Telemetry Data and Training Simulation

About Telemetry

Supply chain companies are increasingly looking to forklift telemetry (sometimes called telematics) to help improve lift truck operations [1], [2], [3].

Practically, specialized devices onboard collect real-time data about where the lift truck is (and where it was), using GPS, and how it’s moving around, using motion sensors,

In particular, the motion sensors detect the following:

• sudden changes in position (forwards/backwards, side-to-side) caused by “aggressive” (possibly unsafe) acceleration, braking, cornering, etc.
• the occurrence of any collision-related “incident”, that might damage equipment or the load (merchandise loss)

In this way, Fleet Managers can track operator performance (and maintenance needs), as this testimonial from [4] makes clear:

“Every day [before telemetry], it seemed [that] two or three forklifts were in the shop, and some of them needed extensive repairs. Now I can look at the report, I can see how the operators are doing, and I can hold them accountable for any impacts they’ve caused, or I can praise them for driving well.”

Still, investing in telemetry requires more than a financial commitment, because Fleet Managers and lift truck operators need to understand what is being measured, and how telemetry “events” are generated.

Of course telemetry data can only tell you what’s already happened, so to improve lift truck operations, you need to work “upstream” and provide better lift truck operator training. And when training simulation “reproduces” telemetry, onboarding with training simulation will help trainees develop operating skills and learn to anticipate telemetry “events”.

Indeed, with the right kinds of “Performance Indicators”, training simulation can tell you much more than telemetry data. In this way, training simulation can help operators learn better, in a simulated world, to prepare for what will happen later in the real world.

About Telemetry Data and Training Simulation

Consider the case of a lift truck backing out of a trailer and (accidentally) colliding with a sidewall. As previously indicated, the onboard motion sensors will “notice” a sudden change in position (forwards/backwards) and thereby detect the collision-related “incident”.

But backing up and (accidentally) colliding with a load or an obstacle (that’s behind the lift truck) will be detected by the motion sensors in the same way, and so recorded as the same “event”.

Well in Simlog’s simulated world, we “detect” (and record) much more, making simulation a powerful operator training tool.

Continuing with the example, our “Stand Up Counterbalanced Lift Truck” simulation software includes a Simulation Module associated with loading a trailer.

Practically, there are 3 Performance Indicators to report 3 different kinds of collisions:

• the lift truck colliding with a load
• the lift truck colliding with the inside of the trailer (floor or sidewalls)
• the lift truck colliding with an obstacle.

These are all collisions that telemetry would measure but if they all occur in the same way (by backing up), then they will all be detected and recorded, as the “same” event. Perhaps more problematic, the telemetry data can’t “tell” you where the contact took place, i.e. what part of  the lift truck collided with what part of the real world.

Well Simlog’s training simulation can do more, by making collisions visible.

As shown in this screen capture image above, our functionality “places” a red collision marker on the lift truck at the point of contact and another red collision marker on the rack.

Later, when the trial (exercise) ends, the simulation software will present all the collisions that occurred, with “paired” red collision markers, to “remind” the trainee about what happened (and what shouldn’t happen again).

In this way, new operators will “naturally” learn to work carefully, so slowly.  Later, after enough “drill and practice”, they pick up speed, while still working carefully.

Finally, when they can consistently complete simulation exercises quickly and carefully, i.e. with no collisions (so no red collision markers), they “graduate” to the real world.

And that’s how training simulation “upstream” will help you better train your lift truck operators, and thereby improve your lift truck operations, made evident by improved telemetry data.

References

[1] “Understanding Forklift Telemetry for Optimal Fleet Management”, Toyota Forklifts Blog, 2025, https://www.toyotaforklift.com/resource-library/blog/digital-solutions/understanding-forklift-telemetry-for-optimal-fleet-management

[2] “Create a Safer and More Efficient Workplace with Clark Smart”, 2025, https://www.clarkmhc.com/parts/clark-smart/

[3] “Crown Infolink Forklift Monitoring System”, 2025, https://www.crown.com/en-ca/fleet-management/infolink.html

[4] Bond, J., “New Forklifts and Telematics Streamline Operations”, Material Handling 24/7 Magazine, 2019, https://www.materialhandling247.com/article/new_forklifts_and_telematics_streamline_operations