Specialist in upscale metallurgy Aubert & Duval revolutionizes operations and efficiency with LiftTrak
Aubert & Duval, established in 1907, has emerged as a prominent global leader in providing metallurgical solutions. The company specializes in the design, development, and production of high-performance steel, superalloy, aluminium, and titanium components.
Renowned as a major supplier to the aerospace industry, Aubert & Duval operates with a workforce of 1140 employees across 11 buildings sprawled over 23 hectares.
The challenges
With an annual usage of 10,000 tonnes of metal and handling 3,000 movements of parts daily, the company faced significant operational challenges that impacted its efficiency and operations.
Inefficient workflow processes, involving up to 15 production stages per customer order, led to delays, worker stress, and potential safety hazards. Inventory management was another major issue as incorrect stock information often resulted in wasted time locating parts. Additionally, unique part designs were shipped to incorrect customers, breaching data privacy, compromising confidentiality and leading to customer complaints. Finally, forklift drivers had to record item movements manually, resulting in errors and time consuming delays.
Aubert & Duval needed a solution to streamline their operations with these main requirements :
- Tracking system to work both indoors and outdoors with an outdoor area of 53,812 ft2
- Simplified operations for workers
- Cost-effective solution due to extensive operational area to cover
- Compatibility with SAP system
- Non-battery reliant solution to withstand extreme temperatures
The solution
With RFiD Discovery’s new LiftTrak system, Aubert & Duval can now provide real-time tracking of aerospace parts both indoor and outdoor tracking without the need for fixed infrastructure.
Each item is equipped with a battery-less RFID asset tag, and UHC RFID readers are mounted directly on the forklift trucks.
These readers detect reference position tags mounted on each shelf, allowing them to determine the exact location where an item is picked up or dropped. In the outdoor area, the system updates item locations via GPS tracking. The location data is sent to the software, offering real-time visibility of the assets and eliminating the need for manual scanning.
The results
More than 6,000 units were tagged, and six forklifts were outfitted with the LiftTrak system. Aubert & Duval saw significant boosts in productivity and safety, as drivers no longer needed to dismount the forklifts, reducing manual tasks by up to two hours per week. This change led to a 75% reduction in handling time, equivalent to the workload of up to three full-time employees (FTEs). Additionally, the time saved in locating the correct items is estimated to be equivalent to one FTE.
Safety improvements were also notable, thanks to fewer forklift movements and the elimination of the need for drivers to dismount for item recording, which is now fully automated.
The forklift fleet is now better managed and optimized, resulting in more efficient use of the equipment. Route optimisation for forklifts has saved considerable time, enhancing overall operational workflow.
Watch the case study
Right from the beginning, and despite the challenging conditions on the ground, our logistics team demonstrated strong involvement, made possible by a supportive setup. During the initial dynamic tests, the system quickly proved successful and demonstrated real potential.
Today, after a few necessary adjustments, the RFiD Discovery LiftTrak solution operates completely autonomously and has delivered improvements in safety, efficiency, and productivity.
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Aubert & Duval revolutionizes operations with LiftTrak
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