Material Flow Tracking

Transcription

1 Material Flow Tracking Product description ABF Industrielle Automation GmbH Deggendorfstraße 6 A-4030 Linz +43 (0) office@abf.co.at Gustav Buchberger;Christian Hiebl

2 Contents COMPLETE SOLUTION FOR IN-PLANT LOGISTICS PROCESSES... 3 FROM FORKLIFT TRUCK CONTROL SYSTEMS TO WAREHOUSE MANAGEMENT, RIGHT UP TO THE TOTAL SOLUTION... 5 PRODUCTION AND GOODS RECEIVING... 6 PRODUCTION CONNECTION... 6 TIMELY TRANSPORTATION OF MATERIALS FROM THE PRODUCTION UNITS... 6 SUPPLYING THE UNITS WITH MATERIAL... 6 AUTOMATIC DATA TRANSFER... 7 DELIVERY... 7 MATERIAL IDENTIFICATION... 7 INCOMING GOODS INSPECTION... 7 WAREHOUSING... 7 QUALITY INSPECTION... 8 QUALITATIVE BLOCK / RELEASE... 8 SAMPLING... 8 TEST DATA... 8 STOCK MANAGEMENT... 9 INTEGRATED STOCK MANAGEMENT... 9 CONNECTION TO STOCK MANAGEMENT SYSTEMS... 9 INVENTORY... 9 WAREHOUSE MANAGEMENT INTEGRATED WAREHOUSE MANAGEMENT AREA STORAGE DYNAMIC AREA MANAGEMENT BLOCK STORAGE HIGH RACK STORAGE (MANUALLY OPERATED OR FULLY AUTOMATIC) CANTILEVER WAREHOUSE FLOW DRIVEN WAREHOUSE ADMINISTRATION UTILITY FOR WAREHOUSE MANAGEMENT WAREHOUSE OVERVIEW VISUALISATION CONNECTION OF EXTERNAL WAREHOUSE MANAGEMENT SYSTEMS MATERIAL TRACKING Version Page 1

3 INDIVIDUAL PART TRACKING ON A MATERIAL LOCATION LEVEL POSITION RECORDING WITH PRECISE COORDINATES VALIDATED RECEIPT OF GOODS TRACEABILITY MATERIAL FLOW CONTROL FORKLIFT TRUCK CONTROL SYSTEM / CRANE CONTROL SYSTEM DRIVING ORDERS VEHICLE VISUALISATION DATA RECORDING VISUALISATION / NAVIGATION / REPORTING FULLY AUTOMATIC CONVEYING SYSTEMS ASRS & AGV SAFETY / LOCKS FULLY AUTOMATIC SELECTION OF VEHICLES (TRANSPORT OPTIMISATION) AND TARGET LOCATION FINDING (OPTIMISATION WITH DYNAMIC SET OF RULES) DYNAMIC SET OF RULES: PICKING DISPATCH DISPATCH PLANNING SENDING PREPARATION HGV CONTROL SYSTEM LOADING TECHNICAL CHARACTERISTICS Version Page 2

4 Complete solution for in-plant logistics processes High-performance warehouse management Receipt of goods Integration of production units Stock management Warehousing / removing from warehouse / relocating Order picking Inventory support Loading Dispatch Material tracking Material tracking on a warehouse level Precise to the centimetre in the coordinate system Vehicle location and vehicle tracking Integration of vehicle sensors Material flow control Steering fully automatic cranes Integration of ASRS, AGV Forklift truck control system Dynamic selection of means of transport Automatic target location finding Transport and warehousing optimisation Visualisation / evaluation Online visualisation in 3D Historic traceability of all movements Vehicle overview Vehicle data / statistics Transport orders / execution of transports Navigation for forklift trucks / HGVs / tractor units Collision warning system Visualisation of vehicles in the immediate vicinity Collision warnings optically / acoustically Diagnosis & simulation Version 1-2 For target site identification For selection of method of transport Page 3 Utilisation rate of resources

5 The OneBase MFT logistics solution integrates a high-performance warehouse management system with continual material tracking, and a fully automatic situation-adaptive material flow control for the in-plant logistics processes. With a multitude of modules, this flexible total solution forms the basis for modern logistics. No matter whether you transport your material with forklift trucks, cranes, AGV or fully automated storage and retrieval systems; all vehicles and materials are tracked in real time. On the basis of this tracking, the material movements are posted automatically. In this way, you always have an overview of where each individual part is located within your logistics chain. Optimisation algorithms and a dynamic, adaptive set of rules automatically ensure the ongoing calculation of the necessary transport orders for quick processing of all the required in-plant material transports. This situation-dynamically optimised real-time procedure leads to efficient usage of the available warehousing and transport capacities. From receipt of goods and material transfer by the integrated production units, to the logistics processes of the various warehousing stages, to picking, dispatch preparation and dispatching; with the OneBase MFT logistics solution we offer an extensive and high-performance complete solution for all functional requirements of your logistics processes and sequences. OneBase MFT brings you maximum efficiency and transparency for your internal logistics processes. Version Page 4

6 From forklift truck control systems to warehouse management, right up to the total solution A multitude of modules enables the realisation of your internal logistics. In this way, OneBase MFT can also be operated as a sub system for an existing warehouse management system. Due to flexible configuration and adaptation, customer-specific requirements can be fully realised, so that OneBase MFT completely adjusts to your business (and not vice versa). Forklift truck control system Crane control system 2D / 3D Visualisation Order handling Positioning Sensors Collision warnings Navigation Material posting Order generation Target location finding Means of transport management Warehouse Manager Administrator Inventory Correction Reporting History Player Disposition Warehouse layout Means of transport Transport paths Configurator Partner Interface ERP L2 / MES / BDE Machine integration Version Page 5

7 Production and goods receiving Production connection Timely transportation of materials from the production units Production units normally have buffer spaces for the transfer of the materials to logistics and/or the appropriate transport devices. These buffer spaces mostly have a limited capacity. The materials must therefore be transported in a timely manner, so that this does not have a negative influence on the production units. The fully automatic generation (see adaptive, dynamic set of rules) of corresponding transport orders and driving orders, with automatic selection of means of transport, and optimised target location finding (see chapter material flow control) ensures free buffer and transfer spaces at all times. Examples: Supplying the units with material Material requirements by production units are automatically processed with high priority by the material flow control in OneBase MFT, and result in transport orders to provide the appropriate units with suitable primary materials. Example: Version Page 6

8 Automatic data transfer Data available to the production units (e.g. status, weight, parts counters, nearest work place etc.) are automatically transferred, saved in the material data set, and, if necessary, used as parameters for further logistics processes (e.g. vehicle selection, target site identification). Delivery Material identification Various possibilities for the identification of the delivered materials (first pick up identification) Manually by dialogue Barcode / QR code RFID Incoming goods inspection Material Characteristics Quantity, weight Quality Warehousing The warehousing of the delivered materials is carried out interactively or automatically. The warehoused materials are booked to a storage location (even with precise coordinates) and into the warehouse management stocks. Version Page 7

9 Example: Quality inspection Qualitative block / release On the basis of transferred production data, measurement values and / or inspection results, the materials receive their quality-related status. This status assignment can occur automatically on the basis of set rules, or corresponding quality user interfaces. Examples: Sampling Inspection regulations and / or inspection plans form the basis of the sequences in the areas of test centres, and are often the basis for decisions in material flow control. Corresponding transport orders for sampling are automatically produced by OneBase MFT and passed on to the relevant suitable means of transport in a timely manner. Test data Test data is collected and allocated to the materials online, or via manual entry according to the relevant available test equipment connection. Qualitative characteristics derived from this influence the further logistic processes if applicable. Version Page 8

10 Stock management Integrated stock management The OneBase MFT logistics solution offers a complete, continual stock management in real time. The corresponding quantity units such as Number of units Kilogrammes Cubic metres Batches etc. are permanently entered into the warehouse management core of OneBase MFT in connection with logical storage locations and / or storage levels for Primary material Semi-finished material Finished material Operating material Auxiliary materials. Connection to stock management systems Existing stock management systems (e.g. SAP ERP) can be connected to OneBase MFT. Stock-relevant postings are thereby published to the relevant stock management system online. Inventory OneBase MFT offers a permanent inventory, through continual material tracking and stock management. In addition, a multitude of tools and functions are available: Inventory lists Checking out shortfall quantities Logging in difference quantities Rebooking physical storage spaces Storage space overview, storage space allocation Lost & found function Support by tablet PCs Scan functions QR code, barcode, RFID Version Page 9

11 Warehouse management Integrated warehouse management With the integrated warehouse management system, the most diverse storage types and topologies can be operated efficiently. Area storage dynamic area management Examples: Block storage Examples: Version Page 10

12 High rack storage (manually operated or fully automatic) Examples: Cantilever warehouse Example: Version Page 11

13 Flow driven warehouse Warehouse constructions which enable and / or enforce the flow of materials according to the FIFO principle, from the warehousing side to the transfer side. Administration utility for warehouse management Create storage locations Move tool Copying tool Manage transport zones Create method of transport Custom attributes With a warehouse configurator, the layout changes in the warehouse can be carried out comfortably. Thereby, new storage spaces can be created, existing storage spaces can be moved, or storage locations that are no longer required can be dissolved. New means of transport can be easily integrated into the system, and managed in various transport groups / transport zones. In this way, OneBase MFT continually adjusts itself to the operating requirements, even after the initial set up. The most diverse customer requirements can be mapped comfortably, via customer-specific characteristics. All changes to the warehouse configuration can be carried out online and will be considered immediately for the order calculation and target finding mechanisms. Version Page 12

14 Warehouse overview visualisation All configured warehouses, storage areas, zones, rows and storage locations (slots) are presented in the visualisation system with their current material allocation, either two-dimensionally or in a 3D view. The users can thereby virtually move through the warehouse, zoom into storage areas, and look at the data of a material by clicking on it. Examples of a 3D visualisation warehouse overview: Version Page 13

15 Connection of external warehouse management systems Existing warehouse management systems (e.g. SAP WM or EWM) can be connected to the OneBase MFT logistics solution. Material postings are thereby published online to the relevant warehouse management system, on a storage location level. Version Page 14

16 Material tracking Individual part tracking Continual material tracking across the whole transport and storage area, with the integration of production units Conveying equipment (manipulators, conveyors, rollers, lifting beams) Transport routes of forklift trucks and cranes Area storage, block storage, high rack storage, cantilever storage, flow driven storage etc. Transfer stations between the storage areas Loading areas Production units On a material location level All material units (pallet, coil, sheet, container, slab, box, etc.) are allocated to the current storage location. The layout of the warehouse (storage space structure) can be freely configured. The following diagram clarifies the configurable storage structure and the relationships between the individual storage objects. Warehouse Zone Zone Zone Field Field Field Row Row Row Row Slot Slot Slot Slot Material Material Material Material Version Page 15

17 Position recording with precise coordinates Example crane position recording Example forklift truck position recording Position recording via The position sensor of the crane itself Differential GPS LPR by Symeo Optical vehicle positioning by Zeno Track Example forklift truck location (functional principle visual location by Zeno Track) Version Page 16

18 Examples LPR by Symeo (functional principle) Functional principle LPR-A Stationary transponders at known positions are used as reference marks for the position determination of base station. The base station sends out a signal, which will be accepted, processed and reflected back by all transponders. The signal is distributed with light speed, as with all electromagnetic waves. The echo of the transponders is coded in such a way, that it can be clearly allocated to each transponder. From the duration of the signal from base station to transponder and back, the direct distance of these components can be determined. If at least three distances to various transponders are known, then the base station can clearly determine their position from this. Functional principle LPR-B LPR-B devices can be configured as base stations or transponders according to application. All devices have their own ID, via which they can be specifically addressed. To measure the signal duration and therefore a corresponding distance, a time synchronisation (picosecond precision) takes place between the devices involved. The communication from LPR-B occurs in the same frequency band as the distance measurement. In this way, no external WLAN or cable networks will be required to transfer measurement values and other useful data. Validated receipt of goods Combined with continual vehicle position detection, and the connection of sensors on lifting equipment, material movements can be recorded automatically. Alternatively, or in addition to this, the collection of goods can be validated via barcode scan or RFID. Traceability All transports, all warehousing, removals from warehouse and relocations, all transfer locations and all units, which a material and / or product has to go through in the production and logistics processes, are traceable via the appropriate evaluation functions, with all recorded parameters (storage location, vehicle, driver, time, wait time, status etc.). Version Page 17

19 Material flow control Forklift truck control system / crane control system Driving orders Automatic generation and specification of transport orders for forklift trucks and cranes for Provision and disposal of the production units Warehousing / removal from warehouse Restoring / combining / preparation for dispatch Loading Fully automatic control of cranes Vehicle visualisation Example of a 3D view of a forklift truck control system: Version Page 18

20 The operator will be shown the work orders which are available for the corresponding vehicle group / transport zone. These orders are ranged according to priority. By activating an order, the source location and corresponding material are marked. This saves the long search for materials. Data recording Loggin and recording of forklift truck journeys Listed transport orders Routes Times / speed Load / transported material Vehicle status Possibly available additional vehicle data Traceability example of all trips: With the History Player, the trips of means of transport (of any kind) can be analysed retrospectively. Thereby, there is the possibility of linking telemetry and position data. Historic linking of sensor with position data Detailed analysis of almost collisions History Player Version Page 19

21 Visualisation / navigation / reporting Online visualisation of status, position, direction of travel, speed and loading of all vehicles Optional visualisation of additional measurement values, available from the vehicle or the sensor, such as temperatures, pressures, engine data etc. Traceability of all journeys (History Player) Graphic illustration (optional in 3D) of all storage areas with the stored materials and their parameters Evaluation function according to all parameters of the storage places, transport vehicles and materials Warehouse and transport statistics History of material movements, processing of driving orders Optional possibility for integration of Additional vehicle sensors e.g. weighing device, tyre pressure, Easy Key, RFID Reader, etc. Coordinates of obstacles relating to collision avoidance Control of additional lights or automatic gates, depending on the current vehicle movement Example of collision warning Data collection Coordinates Direction of movement Speed Collision Warning and alarm signals Version Page 20

22 Example of a 2D view Crane control system Vehicle position Current operating mode Storage location assignment Error diagnosis Messaging system Version Page 21

23 Fully automatic conveying systems The OneBase MFT logistics solution integrates functions and interfaces to control automatic conveying systems such as Belts Roller conveyors Lifting beams Shuttles Overhead tracks Paternoster Etc. Examples: Version Page 22

24 ASRS & AGV Functions and interfaces for the integration of automated storage and retrieval systems and automated guided transport vehicles, in the superordinate vehicle tracking, data collection, material tracking and material flow control by OneBase MFT. Examples: Image Safety / Locks Controlling of traffic lights Entry permit to transfer locations Roll door control Locking crane clamps, magnets etc. if the current coordinates do not correspond to the target location Collision warning when approaching various vehicles Monitoring crossing bans Monitoring speed restrictions Warning for load acceptance by unsuitable vehicles Version Page 23

25 Fully automatic selection of vehicles (transport optimisation) and target location finding (optimisation with dynamic set of rules) In the various logistics processes, transport requirements are either carried out fully automatically in the OneBase MFT logistics system, interactively or via interfaces from neighbouring or superordinate systems e.g. System supply Removal Warehousing / removal from warehouse / restoring Loading Picking On the basis of such transport requirements, the materials / transport goods to be transported, and the suitable method of transport are selected using a dynamic set of rules, and the best possible target location is determined. From this, the driving orders arise for the individual transport steps or corresponding driving order chains, whose processing (manual by vehicle driver or fully automatic) ensures the best possible efficiency and capacity in relation to the existing resources. Examples for material flow control target location search and optimisation Product-dependent storage requirements and material parameters Subsequent processing steps and / or production units Current assignment of vehicles, transfer points and storage locations Planned wait times and current warehouse capacity utilisation Reduction of manipulation activities (excavation) The shortest possible routes, taking into account the current vehicle positions Uniform use of transport capacities of cranes and forklift trucks, taking into account maintenance tasks Examples for locking and safety measures related to this Informing cranes about driving destinations of the forklift trucks (transfer points) Blocking transfer points for forklift trucks, if a crane is in the safety area Blocking the manipulation area of the crane if a forklift truck approaches the transfer point Controlling the lights at the transfer points, on the basis of the current forklift truck position and the driving destinations Version Page 24

26 Driving orders OneBase MFT Material Flow Tracking Dynamic set of rules: Customer-specific logistics processes can be illustrated simply with a dynamic set of rules. Transport goods Storage space Means of transport Signals Characteristics Characteristics Characteristics ID Weight Dimensions Colour Temperature Position Stacking height Coordinates Transport path Weight Max. load bearing capacity Transport requirement RULES Administration utility for ruleset: Set of rules Version control Rule sequence Rule parametrisation Transport classes Rule simulation Version Page 25

27 Picking Picking functions are available for Customer orders Transport orders Internal orders All picking functions are integrated in the warehouse management or respectively in the material tracking, and automatic material flow control, so that an activated picking order triggers the automatic transport and driving order generation for the required material units. Apart from the automatic picking function, OneBase MFT also supports the various manual picking methods. Example Manual picking: Version Page 26

28 Dispatch Dispatch planning OneBase MFT has dispatch planning functions for various types of dispatch: HGV dispatch Train dispatch Customer orders Order combination Internal delivery Sending preparation Sending preparation Preparation of goods to be sent In times outside of the loading window Depending on the available means of transport even fully automatic Examples: Version Page 27

29 HGV control system HGV registration with the concierge Management of loading places / loading zones / loading place allocation Monitoring loading Load securing & documentation Deregistration Loading Automatic generation of transport orders for the materials to be loaded Driving orders for the relevant suitable loading forklift trucks or cranes Management of loading appliances Examples: Version Page 28

30 Technical characteristics Modular construction for maximum flexibility Implementation of the whole OneBase MFT logistics solution using state-of-the-art software technologies Available for different operating system platforms Based on online communication platform OneBase for real online ability every configuration change is online immediately without restarting Supports various relational database systems such as Oracle or SQL server as standard Full redundancy due to clustering on the level of the online database, and therefore hot standby possibility Mobile terminals (vehicle terminals and tablets) via WLAN with buffered communication Online 3D visualisation Continual vehicle position detection Integration of vehicle sensors Integration of the control system of cranes, vehicles and conveying equipment for position and data collection and locks Interfaces to MS-Office Web portal Adaptive, dynamic set of rules for optimised driving orders, taking into account the current situation and utilisation of all integrated resources Evaluation and simulation of rule processing for transport order generation Coordinate-, speed- and situation-dependent data collection and data transfer Traceability of all vehicles and material movements, via graphic visualisation Multi-client capability for several different warehouses or different factories and storage areas on one server or cluster Version management with rollout support and automated release change functionality Version Page 29