Case Study

Project Manager: Digitalization of Intralogistics

Our Role: Overall Project Management

Our client

Polifilm Group

08/2024 - 05/2025

Digitalization and modernization of intralogistic processes with a focus on modern sensor solutions.

Planning and implementation of smart sensor solutions for monitoring material flows, inventory levels, and vehicle movements in production. Deployment of UWB/GPS modules, distance sensors, and collision warning systems.

Connection to PLC, MES, WMS, and Microsoft Dynamics 365 for real-time control, data analysis, and automated alerting.

Initial Situation | Objectives

Digitalization of forklift and warehouse processes using modern sensor technology
Real-time monitoring of positions, movements, and statuses
Integration with central control systems (PLC, WMS, MES)
Introduction of a disturbance detection escalation system

Duties | Responsibilities

Project planning and overall coordination
Selection, procurement, and integration of sensor hardware in vehicles and warehouse technology
Interface design and connection to existing control systems (PLC/WMS/MES)
Management of collaboration with manufacturers and operational technology

Key areas:

Overall coordination of sensor technology introduction in intralogistics
Selection, configuration, and integration of sensor hardware (e.g., from ifm, Sick, Pepperl+Fuchs)
Equipment of industrial trucks with distance sensors, GPS/UWB modules, and collision avoidance systems
Integration of Sensors in High-Bay Warehouses for Status Monitoring (e.g., State of Charge, Temperature, Movement)
Integration of systems to PLC, WMS, and MES platforms for real-time evaluation
Development of a multi-stage alerting and escalation concept
Coordination with operations engineering and monitoring of installations
Performing test scenarios under real production conditions
Training of specialist personnel and creation of technical documentation

Technologies & Methods

Distance sensing
GPS/UWB Tracking
SPS controls
WMS/MES
ifm
Sick
Pepperl+Fuchs
Alarm and escalation logic
Project Management (traditional/agile), Operations Technology Integration, Change Management

Overall project management

Results

Weidehoff Business Solutions

Successful digitalization of in-house logistics processes
Real-time monitoring of vehicles and warehouse positions
Significant reduction of security risks and disruptions in warehouse operations
Early detection of technical error states through escalation logic
Positive feedback from operations/engineering regarding efficiency and overview.