Parker Tracking System (PTS) White Paper No.101 Global Asset Tagging & Identification System for Hydraulic Hose Assemblies William E. Sayavich, Business Development Manager Parker Hannifin Corporation, Hose Products Division wsayavich@parker.com INTRODUCTION Parker s Hose Products Division headquartered in Cleveland, Ohio, launched the Parker Tracking System (PTS) in October 2009. The system is for all new Parker-manufactured OEM and distributor assemblies that the company makes. PTS provides fast, accurate and convenient hose assembly replacement regardless of where or when the original assembly was made. This global asset tagging and identification system has two key components. First, PTS features a unique and visual alphanumeric identification label (Figure 1). Using one of several billion random and unique codes, no two hose assemblies will ever share the same PTS number. This enables authorized distributors to quickly and accurately replace a hose assembly just by using the PTS identification number found on the label. Barcodes and optional RFID (Radio Frequency Identification) technologies are used to enhance identification and reduce errors. The PTS database can be accessed securely for component level detail and other key data that Parker or the customer may include within the electronic record. This information may include such detail as VIN, vehicle or model information, hose installation or port information as well as other data the assembly owner or OEM may want to include. The labels are generated by specially selected printers and are affixed to each hose assembly at the time it is made. The second component is a powerful Web-based software system that is accessed securely through the Internet. The new PTS program eliminates the need for customers to first remove old hoses before a new assembly can be made, thus making call ahead or site delivery options possible. The result is additional machine uptime that can dramatically improve the customer s operational efficiency and bottom line. Figure 1 PTS standardized labels with Parker s unique identification number. 1
Parker Tracking System (PTS) Global Asset Tagging and Identification System for Hydraulic Hose Assemblies CONTENTS PAGE Parker Tracking System (PTS) Detail... 3 PTS Product Features... 3 Captured Information... 3 PTS Web-based Database Engine... 3 PTS Labels and Associated Hardware... 3 Research and Testing... 4 Value-In-Use... 4 Equipment Users... 4 Value Example... 5 Parker OEM Customers... 5 Application Example Australia s Mining Standard... 5 More Information... 6 Parker s Winovation Process... 6 About Parker s Hose Products Division... 6 2
PARKER TRACKING SYSTEM (PTS) DETAIL PTS Product Features Historically, the only way to secure an accurate replacement hose assembly was for the customer to bring the entire assembly to a store, and for a counter technician to make an educated judgment as to the necessary components. Worn part numbers or incomplete assemblies made replacement more difficult and time consuming. Document the date and cause of replacement; compile and report results Offer data analysis to help drive preventive maintenance programs Customize the label with kit or assembly instructions Captured Information Component detail and other key data that Parker has within its system are automatically loaded into the PTS database. This information includes: Customer information and part number Bill of materials hose, fittings, accessories, etc Kit numbers, assembly instructions or industry certifications With PTS, additional features include: Inventory management Asset tracking Warranty verification Assembly verification Failure analysis reporting MRO Original equipment performance assurances Protection against counterfeiting Figure 2 Distributors can quickly retrieve replacement information with a barcode reader or users can call-in the ID number. With PTS, replacement hose assemblies can be made using only the unique ID number found on the PTS label (Figure 2). Customers can even call ahead with their PTS ID and the distributor can retrieve the assembly details including hose and fitting part numbers, assembly length, optional sleeving and accessories. The Parker Tracking System has the ability to: Capture, record and recall all pertinent hose assembly information on demand Provide fast, accurate and timely identification and replacement of assemblies regardless of where the original assembly was made; this eliminates the need to remove hoses prior to replacement Provide critical machine uptime and a more conveniently scheduled repair Provide phone-in replacement order convenience, making faster site delivery (not site repair) possible The unique 8-digit alphanumeric identification code on U.S.-produced labels is fully compatible with PTS systems installed at Parker distributors throughout 18 countries in Europe, the Middle East and Africa since 2007. As such, PTS is a true global solution for Parker customers and OEM business partners. PTS Web-based Database Engine The PTS software application is a powerful Web-based database engine accessible securely by Parker, its OEM business partners and distributors around the world. What makes the Parker system unique is that it is not only an in-house tagging and tracking system; Parker s global distributor network and its OEM business partners will also use PTS for the assemblies they make in-house. PTS Labels and Associated Hardware Parker partnered with a prominent global manufacturer to develop a proprietary label that would withstand the wide variety of conditions to which hoses are subjected. 3
Research and Testing PTS labels and the affixing adhesive were performance tested in three separate laboratories including Parker s state-of-theart materials lab in Wickliffe, Ohio. Label materials were tested for extreme cold, heat, UV and moisture along with a number of fluid types including fuel, hydraulic fluid, water, Skydrol and others. Additionally, lab staff tested each label with equipment that simulates a variety of aging and extreme conditions. Labels were also submerged in heated hydraulic fluids for extended time periods to ensure continued adhesion and readability. All PTS labels are standardized with both readable text as well as barcodes for Parker s unique ID number and the customer s part number (Figure 3). The labels can also be offered with EPC Global compliant Gen 2 RFID tags that have been specially engineered to provide outstanding read/write performance using both handheld and fixed devices. The RFID labels are also engineered to withstand the same severe environmental conditions as the barcode labels. PTS Label Breakdown VALUE-IN-USE Equipment Users For owners and operators, the value is measured and received in the speed, timing and accuracy of securing a replacement hose assembly. Speed in material and component identification is realized using the PTS ID number (Figure 5). Much like a fingerprint, no two ID numbers are alike. Figure 3 Customized information can be added to the PTS label. The labels are generated using select Zebra printers and RFID encoders. Motorola RFID and Barcode readers are part of the PTS system (Figure 4). Research was conducted to carefully match every aspect of the system including the labels, printers and even the printer ribbons. PTS labels are printed with a thermal process (not ink), which is rated for 10 years of UV protection. Figure 5 Phone-in replacement orders make site delivery possible. Timing is improved as the replacement hose assembly can be ordered and secured prior to the original assembly being removed. This means that a job site can continue to operate while a necessary replacement is ordered; furthermore, that replacement can be scheduled during a more convenient maintenance interval with the replacement already on hand. Replacement accuracy is ensured, since replacing a PTS-tagged assembly recalls the entire original bill of material, including any accessories that are to be included such as guards or sleeving (which may have fallen off during use) as well as cleaning specifications, fitting orientation angles and more. Figure 4 PTS label printer and barcode reader. 4
Value Example Parker estimates that the addition of a PTS label can save a customer at least 15 minutes of downtime (simply stated as the time spent waiting in a store, or as the additional time spent in first removing an assembly before proceeding with the repair). If the average cost of labor and machine downtime is calculated at the low end of $60 per hour, PTS can save the customer $15 in direct productivity losses. operation, the hoses rub against one another. The OEM can now make an appropriate design modification be it re-routing one of the hoses or adding an abrasion-resistant sleeve to the failure-prone hose before the problem becomes increasingly complex and costly. Failure information is also extremely valuable to OEMs because it allows them to guarantee longer run time. If, for example, a machine can run 5% longer before required repairs, the value to the customer is significant. $60 (hour) divided by 4 (15 min.) = $15 per 15-minute interval of downtime For customers with multiple, untimely failures per month, this can add up to considerable savings. Many customers have documented downtime of two to three hours or more due to hydraulic hose failure, and at labor and loss productivity rates of up to $500 per hour or more. In such circumstances, PTS can be invaluable in helping to ensure maximum machine or vehicle uptime. Application Example Australia s New Mining Standard Requirement This new safety standard for Australia s mining industry requires that a hose assembly be physically inspected every 12 months to ensure that it is still in good working condition. The standard also requires hose replacement at the five-year benchmark. With the hose manufacture and install dates in the PTS database, the user will be able to receive an alert that specific hoses on a machine located in a particular section of the mine are due for their annual inspection in the next several days, or that it is time for the hose to be replaced. Parker OEM Customers For Original Equipment Manufacturers (OEMs), the benefits include the ability to deliver to their customers a more intuitive and traceable fluid conveyance system. It is easy to overlook the value of a hose assembly until a failure occurs. Customers can incur thousands of dollars in lost productivity from a single failed assembly. In addition, the PTS tag captures an assembly creation date to help the OEM determine the validation of a warranty. An additional potential benefit is hose failure analysis. If, for example, the PTS database shows that an OEM has experienced a significant number of hose failures within a given month, the OEM can be alerted to this fact immediately. In pinpointing a spike in failures for a specific type of hose on a particular machine, it is further possible to predict the cause of future failures and deploy a solution proactively rather than reactively. For instance, upon inspection, the OEM may find the failed hose is in close proximity to another hose and during machine A mining machine may have 30 hoses in the immediate proximity of a hose targeted for inspection; PTS technology will make it easy to identify the right hose with a positive match, eliminating the possibility of inspecting or replacing the wrong hose. 5
MORE INFORMATION To learn more about the Parker Tracking System, visit www.parker.com/pts or contact Parker Hannifin Corporation, Hose Products Division, at 440-943-5700. PARKER S WINOVATION PRODUCT DEVELOPMENT PROCESS Parker Hannifin Corporation, the global leader in motion and control technologies, launched Winovation in 2003 as a standardized corporate-wide process for product development. Based on an adaptation of the stage-gate practice, Winovation brings together cross-functional business management teams including alpha customers that meet regularly with R&D leaders to measure the progress of R&D initiatives against specific business metrics. The Parker Global Asset Tagging and Identification System is a solid testament to the success that can be achieved through Parker s Winovation process. ABOUT PARKER S HOSE PRODUCTS DIVISION The Hose Products Division is a unit of Parker Hannifin Corporation s Fluid Connectors Group. The Group, headquartered in Cleveland, Ohio, is the world s leading producer of tube fittings, rubber and thermoplastic hose and fittings, brass fittings and valves, quick-connect couplings and assembly tools. 2010 Parker Hannifin Corporation 1/2010 Parker Hannifin Corporation Hose Products Division 30240 Lakeland Blvd. Wickliffe, OH 44092 United States direct 440 943 5700 fax 440 943 3129 www.parker.com www.parkerhose.com