Real-time monitoring in intralogistics and production

Monitoring in intralogistics

Real-time monitoring and visualisation of material flow and provision in intralogistics and production.

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Real-time monitoring in intralogistics and production

Digitalisation is transforming logistics and production. It opens up enormous potential for companies to increase efficiency, reduce costs and optimise processes. Intelligent sensor technology is used in the application of eKanban for small and large load carriers and driverless transport systems. This already simplifies processes in logistics and production and increases productivity, especially for material replenishment in production areas.

ebp-consulting has developed a system for monitoring real-time data in the areas of material flow, material retrieval and material provision. In addition, the status of the sensors used can be visualised and used for proactive maintenance. To this end, ebp-consulting combines the data streams from the sensors with innovative dashboard technology and displays the operating statuses in intralogistics and production in near real time. This supports shop floor operations from a business perspective in order to ensure production supply, e.g. from eKanban applications.

The ebp standard dashboards are adapted to the specific requirements of the customer's respective production in order to achieve the following services:

  • Line-side monitoring with tabular and layout-based visualisation of outstanding replenishment in material provision
  • Real-time identification of process deviations to avoid material bottlenecks and failures in production
  • Support for preventive maintenance/predictive maintenance of the system by monitoring the condition of the sensors used, such as remaining battery capacity

 

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Use cases in real-time monitoring in intralogistics and production

  • Monitoring material requisitions

    • Status of material flow at a glance via key performance indicators
    • Identification of load peaks through peaks in call-off behaviour
    • Visualisation of open call-offs as a table and layout-supported aggregation of all open call-offs at the installation site

  • Line-side Monitoring

    • Display of the current status of all sensors at all KLT/GLT provisioning locations
    • Identification of empty provisioning aisles in a KLT rack
    • Display of the retrieval frequencies of all placements as a basis for further optimisation, e.g. for ergonomics
    • Visualisation of the throughputs of all provisioning as a basis for further optimisation, e.g. for ergonomics

  • System monitoring

    • Central overview of all installed sensors by sensor type and production area
    • Tabular overview of the number of sensors by battery charge status and production area
    • Detailed view of sensors with low battery charge status
    • Layout-based display of all installation locations with sensors that have a low battery charge status for maintenance purposes

Where is the solution used?

The ebp solution can be used across industries in discrete manufacturing and assembly. Real-time monitoring (visualisation) of material flow and provisioning can be used in all direct areas (on the shop floor) of production and logistics. The optimisation of processes in production and logistics is also made possible, for example, in the areas of ergonomics and smoothing of call-offs (levelling).

The following industries benefit from our real-time monitoring:

 

Project collaboration with technology and system provider steute

We are already working successfully with steute Technologies GmbH & Co. KG (steute) in this area. Under its Lean-Tec business unit, steute offers its customers the nexy digital shop floor solution, for which ebp-consulting GmbH provides a standardised dashboard environment. The cooperation combines the consulting expertise of ebp-consulting GmbH with the technological expertise of steute Technologies GmbH & Co. KG. This enables us to offer customers high-quality services in both fields, processes and systems/technology.

Technologie- und Systemanbieter steute

  • Production logistics planning

  • Material flow planning

    • Material flow design
    • Implementation of material flow control systems
    • Implementation of material flow analyses and value flow designs
    • Layout planning of logistics areas and traffic routes
    • Planning and introduction of tugger trains and automated guided vehicles (AGV)
    • Optimization of internal plant transports and traffic using evaluation tools
    • Planning the transport control

  • Intralogistics

    • Optimization of internal logistics processes
    • Definition of warehousing
    • Definition of the optimal material flow from incoming goods to production and outgoing goods
    • Definition of optimal transportation concepts
    • Optimum utilization of logistics and transport areas
    • Planning of super­markets for picking small load carriers and goods­baskets/sets using a wide variety of technologies (including pick-by-light, pick-by-voice or sequencers)
    • Introduction of kanban control
    • Definition of suitable conveyor and storage systems
    • Tendering and selection of suitable logistics technology
    • Implementation support and ramp-up

  • Tendering of logistics services

    • New tender for contract logistics & intralogistics
    • Outsourcing of warehouse logistics & intralogistics
    • Tender management for logistics services
    • Planning, preparation & implementation of tenders for warehousing & transportation services
    • Service-independent tendering
    • Market research of potential logistics service providers and large network of logistics service providers
    • Compilation of customer requirements and development of the service description
    • Preparation of specifications / Request for Quotation (RFQ)
    • Structured, possibly multi-stage tendering process for contract logistics & transport logistics
    • Communication with the logistics service providers (3PL)
    • Systematic assessment and evaluation of service provider offers in terms of costs, degree of fulfillment & quality
    • Creating transparency and comparability of service provider offers
    • Identification of gaps in the offer, pitfalls & risks
    • Accompaniment & support in discussions with providers
    • Transfer of the tender to the implementation / realization phase

  • Logistics benchmarking

  • Lean logistics principles

    • Digitalization of logistics through the development of data models to map technical issues
    • Data procurement and integration into the overarching data model
    • Data preparation, plausibility checks and cleansing
    • Analytics as a service (AaaS)
    • Performance of regular data analyses by our ebp experts
    • Identification of optimization potential in logistics
    • Reducing costs and increasing performance in logistics

  • Containers and packaging

  • Spare parts logistics

  • Waste disposal logistics

  • Logistics optimization with big data analytics

    • Digitalization of logistics through the development of data models to map technical issues
    • Data procurement and integration into the overarching data model
    • Data preparation, plausibility checks and cleansing
    • Analytics as a service (AaaS)
    • Performance of regular data analyses by our ebp experts
    • Identification of optimization potential in logistics
    • Reducing costs and increasing performance in logistics

  • Business intelligence

    • Data­visualization with different data­aggregation on the basis of roles and user­groups
    • Derivation of role­profiles for user­groups from operations to management
    • Creation of standardized and automated reports
    • BI tool­expertise from project­-related application for support in selecting the right tools for digital logistics

  • Internet of things (IoT)

    • Data­visualization with different data­aggregation on the basis of roles and user­groups
    • Derivation of role­profiles for user­groups from operations to management
    • Creation of standardized and automated reports
    • BI tool­expertise from project­-related application for support in selecting the right tools for digital logistics