Planning and Implementing Your Automation...
Transcript of Planning and Implementing Your Automation...
Presented by:
Mark Neuens
Planning and Implementing Your Automation
Needs
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What’s the benefit to using automated warehouse systems?
- High performance operation - High quality operation - Low cost operation
What’s the RISK to using automated warehouse systems?
- If the commercial distribution changes …..
- If the machine stops …..
- If the commercial distribution changes ….. >You can keep using the system effectively if you have a flexible system plan >You can meet future volume needs if you have an expansion plan
What’s the RISK to using automated warehouse systems?
What’s the RISK to using automated warehouse systems?
- If the machine stops ….. >You can keep your business’ operation going if you have a back up plan >You can avoid stopping production if you have a good maintenance plan
How can you create a beneficial auto warehouse system with low risks?
We will provide you with some solution ideas by introducing a case study.
Case study Konoike-Group The first Konoike Group company in the United States was established in 1985, and today we have four companies on the U.S. West Coast. In addition to large freezer and cooler warehouses, we also provide services such as rapid freezing, USDA inspections, and assembly and installation of large machinery and equipment. Our extensive network covering the entire United States enables us to offer high-quality solutions. USA Office -KONOIKE-PACIFIC CALIFORNIA, INC. -KONOIKE-E STREET, INC. -KONOIKE-GENERAL INC. -KONOIKE TRANSPORT & ENGINEERING (USA), INC
Head Office OSAKA, JAPAN
Case study Konoike-Group
30m Stacker Crane x 24 sets Rack support building 41,952 locations
30m Stacker Crane x 11 sets Rack support building 19,228 locations
RGV (Rail guided vehicle) x 30 sets
RGV (Rail guided vehicle) x 25 sets
Layer picking robot x 2 sets
Case conveyer line (Connecting to factory)
Pallet conveyer line
Vertical lifter x 3 sets
Pallet rack x 708 locations
Distribution Center area is 235,105 SqFt Total storage volume of AS/RS is 61,180PL 441,140CS moving/day (Peak day)
Case Study Konoike-Group
The design of this distribution center was created for the following:
1. Warehouse to store the beverage products from the adjacent factory
2. Hub center for shipment to the three prefectures near Tokyo
3. Hub center for direct shipment from factory to the large transaction
customer
Case study Konoike-Group
1. The combination of accuracy and efficiency by the automated warehouse
and flexibility by semi-automated picking
2. The appropriate assignment of the operator who has multiple skills
against changing working volume
3. Maintenance by skillful users make the machine more reliable while
minimizing maintenance cost
4. The truck control system reduces traffic within the warehouse causing a
more environmentally friendly workspace
Concept
This distribution center was designed with low cost operation features
providing interface with machines and users
along with information technology
Material Flow
Case study Konoike-Group
AS/RS
Palletizer x 3
FROM: Factory
Receiving
Store IN from factory
Store IN from outside warehouse
Material Flow
Case study Konoike-Group
AS/RS
Floor Storage
Layer picker x 2
Shipping
Replenishment
Picking
Shipping OUT
Case study Konoike-Group
1. Flexible system plan The number of machines in action can be adjusted based on system needs (RGV)
Case study Konoike-Group
1. Flexible system plan
Manually Operated Area
RGV (Rail Guided Vehicle)
Manual Rack
Case study Konoike-Group
2. Expansion plan
Expansion Line
Expansion AS/RS (Built 4 years after initial operation)
Case study Konoike-Group
3. Back up plan For inbound from the production line
Case study Konoike-Group
3. Back up plan For inbound from the production line
Case study Konoike-Group
3. Back up plan For inbound from the outside
Case study Konoike-Group
4. Good maintenance plan Partnership between the user and the vendor company
Training Daily / Weekly
Teaching Support PM
Work
Daily / Weekly
Support
Hand over On site
User
Vendor Company
Case study Konoike-Group
4. Good maintenance plan Monitoring system
Equipment
Monitoring system
Monitor
Alarm
Case study Konoike-Group
4. Good maintenance plan Remote maintenance
Equipment
Control system
Monitor
Access
Access
Marketing
Sales
Supply &
Demand
Material
Flow
Manufacture
Purchase
Pa
rt/raw
ma
teria
l
sup
plier
Ma
nu
factu
re
Wh
olesa
le trad
e
Reta
il trad
e
Cu
stom
er
Material Flow
Information Flow
SCM Player ・Marketing
・PB / NB
・Web / EDI
・VMI / CRP
・JIT (Kanban)
・OEM
・3PL
・Integrated manufacturing and sales
・Through / Stock
・Fabless ・Visualization
・CPFR ・ECR ・Global Data
Synchronization
・CRM
・Demand forecasting
・Big data analysis
Security / Safety
Changing population (structure)
Global market
Wearables society
Security / Certification
Energy resources
Environmental problems
Compliance
Internet
IT technical growth
Biotechnology
Network
Cloud computer
BCP / BCM
・IoT (Internet of Things)
・Industry4.0 ・IIC(Industrial Internet Consortium)
・Integrated manufacturing and sales
- Technological trend - - Social background -
Wearable Solution
Wearable technology Smart glasses
Camera
Voice recognition Voice composition
Vision recognition
Barcode reader 1D / 2D
RFID reader
Hands Free Abundant Information Flexibility + +
Wearable Solution
Hands Free
The instructions are shown on smart glasses The data is input by voice recognition
Mistakes can be prevented by using the barcode reader with wearable technology
The hands free feature creates an improvement in productivity and helps reduce time consuming work by eliminating time consuming processes. Operators can get instructions and input data during their picking work with fewer stops.
Abundant Information
Abundant information makes instructions easy for beginners. Operators can have instructions shown on the big screen and on the high resolution smart glasses (voice-assisted).
Detail of work instruction
Mapping of location
Work instruction
Flexibility
Flexibility makes the operations for your work style easier. The operator can see instructions in front of them and also work by voice and wearable barcode reader.
Display image (transmission type)
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Case Study of 4 people - conducted a comparative verification of productivity in:
Various Picking /List Picking/Hand Picking
Study: Move product 30m; Order 10items/15case)
Verification
List Picking 3min 38sec Hand Picking 3min 54sec Various Picking Styles 2min 41sec
List picking – The product is visual
Hand picking - Loading and unloading time is longer
Various Picking is “Hands Free”
→ 3~4sec reduction/1item
Order information from:
List picking : Paper / Hand picking : Hand device
Various Picking is「Display agnostic location」 Various Picking can check the location on the move
→ 2sec reduction/1item
Result
Various Picking vs List 26% time reduction Various Picking vs Hand 31% time reduction ※ Wrist picking needs other inspections
Increased Productivity Reduced Training Time
Less Mistakes for Picking Orders
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Real Life Example:
【Current hospital situation 】
Wearable Solutions help improve efficiency in the medical field by allowing medically
untrained workers to use the technology successfully
Easy instructions for beginners in a large display of Smart Glasses (in the form of Hi-Resolution images)
Easier to use because of the multiple instruction features (Looking - Smart Glass & Listening - TTS)
Able to multi task because of the hands-free operation
Prevention of mistakes by barcode items check
Reduction of set-up time because of the automatic preparation detail delivered
Reliable data maintenance, guarantee of data quality because of the data linkage to other systems
Increasing medical cases
Shortage of nurses
Need to confirm medical safety
①surgery order management ②linkage to host system of surgery order ③surgery order (new, change, delete) ④ quantity change function of preparation order ⑤ preparation indication, progress management -Barcode check (item, expiration date) -work on hold, item shortage
①Instruction to return to the shelf ②Return result Management (CSV output) Validity support of surgery type
SaaS提供
オンプレミス
① medical material , medicine and medical instrument master management ② department and doctor master management ③ surgery type and doctor another surgery type master management ④ various master data linkage to host system ⑤ various master maintenance (add , change , delete)
Return unused items
Various types of management
software
Preparation features
On-premise
The Cloud
【Japanese Red Cross Society Kyoto Daini Hospital】
The number of authorized beds :680 beds
Running number of beds :639 beds
The total number of outpatients (2013 FY) :373,475
The total number of Patients (2013 FY) :206,330
Operating rooms :10 rooms
Number of operations (2013 FY) :6,826 /648 type operations
5,509 / 282 648 type operations(using OPSS)
Medical materials :over 350 items
Main operation time :10:00~14:00 (running hour 3 hours /1day)
Needed items for each operation :51 items (max), 12 qt / 1 item(max)
【Efficiency of Installation】
・ 2 assistant nurses were relieved from overtime work -
temporary staff can operate work by herself/himself
・Startup education for first-time staff was reduced to 2 hours
・Operation time has become 15% faster
・Nurse on duty has decreased more than 3 hours per day
Remote Service Support System
Remote Support System
Remote monitoring Solutions
Software Designer
R&D
Technical Support
AMHS Control System
Smart Remote Controller
Monitoring AMHS Support system
Warehouse Management System
Automated
Material
Handling
Systems
Image management server
On-site Support On-site Maintenance
Remote Support Remote Maintenance
Support of stable operation ● High accuracy Preventive maintenance
● High accuracy Predictive maintenance
● Support of PM to Customer Stuff
KAIZEN of operation
KAIZEN /Change of facilities ● Logistics improvement proposal
● Proposed operational improvement
● Optimal system operation proposed
Savings in maintenance
costs ● Planning of High accuracy Preventive
maintenance
● Optimize the equipment inspection in
cooperation with the history and condition
monitoring
● Optimize component exchange in
cooperation with the history and condition
monitoring
Shortening of the recovery
time ● High accuracy by remote monitoring
cause investigation Rapid measures
implemented in cooperation
● Each expert staff on-site support in
real-time
Integrated control management system
Connection Management System
People and people of remote communication system
The site and field engineers, technical support and software engineers, designer, R&D (such as the technical expert) can
all remote in at the same time for logistical support. Each of the experts can support the fieldwork as if they are there, to
achieve a quick solution to the problem.
Internet (Encrypted
communication)
Remote Site Manager
Designer R&D
Technical Support
Customer Record
Customer
Record
Customer information
Site environment
(Site Conditions)
Exchange module management
(S-BOM Cooperation )
Replace History information
Design Documentation
Procedure of Error recovery
System Configuration
Software
Field engineer
Voice Chat
Multiple voice
conversation
Text Chat
Text
conversation
that does not
miss the
important
conversation
Live Chat
Live video field
situation
White Board
To understand
and use the
documentation
and on-site
Use the Tablet PC / smart glass in accordance with the work
Wearable Solution
Audio and video
Audio data at the time of work
・Voice recognition ・Text recognition
(Automatically generates work reports)
Work report data
Big Data Analysis
Optimization
Best practice
Analysis of the results report
Automatically collects accurate reports
Achieves the big data analysis
Realize QCD improvement:
Maintenance Quality
Inspection Site
Management Shop
Management
Home Care Emergency
medical care Nursing care
KAIZEN
Improvement After follow Proposal
Home care
Maintenance
Site Management
It will connect people to people & people to systems in various fields! !
Device free by browser use (not required, special equipment and installation)
It does not matter the location(Intranet / Internet / Wifi / Encrypted communication )
System Linkage(Maintenance / Home care etc.)
User interface tailored to the business and user
Quality Inspection
Shop Management
Nursing care
Emergency medical care
For More Information:
Mark Neuens: [email protected]
www.storageandretrievalsystems.com
Nikki Edmondson: [email protected]
www.storageandretrievalsystems.com
Or visit MODEX 2015 Booth 4447