THE CONNECTED DISTRIBUTION CENTER · •Reduce maintenance labor costs up to 20%; spare parts /...
Transcript of THE CONNECTED DISTRIBUTION CENTER · •Reduce maintenance labor costs up to 20%; spare parts /...
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved. Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Business Results Through Digital TransformationTHE CONNECTED DISTRIBUTION CENTER
O P E R AT I O N A L A N D B U S I N E S S E X C E L L E N C E A C R O S S T H E E N T E R P R I S E
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E-commerce
and e-retail
DISTRIBUTION
VOLUME
ACCELERATING
at a rate of
MANUAL
OPERATION
is today’s norm for
Industry growth
OUTPACES THE
LABOR POOL
by a ratio of
A positive delivery
experience means
REPEAT BUSINESS
for80% OF D C s
S IX TO O N E
25%
A NNUA LLY
73% OF
C ONSUM ER S
THE MARKETPLACE
FOR CONNECTED DISTRIBUTION CENTER
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Pace of Change in Today’s Commerce Environment Is Relentless
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BUSINESS PRESSURESENDLESS COMPLEXITYEVER-INCREASING SPEED
• Continued acceleration of e-
commerce and e-retail order volumes
• Massive increases in mobile device
orders
• Heightened consumer expectations
for delivery and accuracy
• Increased product and package
variability
• Workforce scarcity and skill set
mismatches
• Hardware-software-sensor integrations
from component to system to operation
• Margin reduction
• Service level commitments
• Capacity constraints within existing DCs
• Geographic expansion to meet
customer demands
Maximum throughput Intelligent, data-driven, high-speed execution
Complete flexibility
Future-proof scalability
Actionable intelligence
Automated, adaptable processes for machines and workers
Optimized utilization with ability to seamlessly adapt and expand
Insights and predictive analytics, from sensors to the cloud
Situation
Customers’
Accelerating
Requirements
Connected
Distribution
Center
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An accessible, end-to-end capability designed to drive efficiency and optimized decision making
with unparalleled visibility and agility, from a single asset to the entire enterprise
Assets
Systems
Robots
Freight
Workers
Enterprise
Third-PartyProviders
Other Distribution
Centers
WHAT IS
THE CONNECTED DISTRIBUTION CENTER?
Achieve Operational and Business Excellence via Digital Transformation
Distribution Center Overview
Pace of Change in Today’s Commerce Environment Is Relentless
• Ever-increasing Speed
• Endless Complexity
• Business Pressures
Worker
Assets Systems
• Predictive asset health and performance
• Improved information visibility and data analytics
• Productivity, safety and reduced attrition
• Scalable, configurable, extensible software
• End-to-end solutions/ improved visibility
Improve utilization;
Reduce CAPEX spend
Increase reliability;
Reduce OPEX spend
Maximize productivity,
consistency and
attrition
Logistics
• Package location and condition tracking
Reduce product loss
and waste
Robot
Intelligence/Analytics With Honeywell Sentience
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Momentum Warehouse Execution System (WES)
• With extensive modular functionality, flexible integration protocols and clear
upgrade paths, Momentum WES is designed to reduce the complexity of
custom development and give you the tools you need to:
- Maintain visibility of fulfillment activities
- Access unified controls
- Achieve automation-driven efficiencies
• It’s that simple.
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Redefining WES: Warehouse Execution. Simplified.
Warehouse Optimization Powered by Momentum
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BI & ANALYTICS
CONFIGURABLEMASTER DATA
MOMENTUM CONNECT
SCALABLE ALARMS & EVENTS
TASKS EXTENSIBLE
MACHINE CONTROLS
& PLC INTERFACE
At the core of Momentum is a suite of services
designed to connect your warehouse systems
• Momentum Connect:
Interfaces with your host system (WMS)
• Master Data:
Stores item master and more
• Business Intelligence & Analytics:
Provides enterprise level reporting
• Alarms & Events:
Sends notifications of events requiring attention
• Tasks:
Creates and assigns segments of work
• Machine Controls & PLC Interface:
Interfaces with mechanical systems
Momentum Modular Solutions*
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ORDER EXECUTION
PICKING
MOMENTUM CORE
ROUTING
LOOP SORTATION
LMS
LINEAR SORTATION
PRINT AND APPLY
PUTWALL
AS/RS
BUFFER
INVENTORY
GTO PICKING
PUTAWAY
AGV
LABOR OPTIMIZED ROUTING
AMR
SHIPPING
SCALABLE
CONFIGURABLEMODULAR
EXTENSIBLE
* For illustration purposes, not intended to be a comprehensive list of existing or future functionality
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Asset Reliability — Use Case for Distribution Centers
Transition to predictive maintenance model, minimizing unplanned downtime and reducing total annual
maintenance cost (material and labor)
Value
Opportunity
Solution
• Reduced unplanned downtime
• Predictive maintenance, reducing reactive and preventive hours (20% - 35% reduction = $40K annual savings)
• Reduced annual maintenance material spend (30% reduction annual parts spend, 20% reduction inventory value = $140K annual
savings)
Data collected from
controls and edge
Maximum uptime,reduced maintenance cost
Cloud-based event/fault detection
SECURED DATA
Asset model insights
Material Labor
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2
5
3
Automated maintenance planning
4SENSORS
CONTROL NETWORK
750k sq. ft. DC, operating 5,200 hours
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Asset Reliability — Use Case for Manufacturing
Real-time monitoring, diagnostics and asset-level insights help increase reliability and improve utilization
Value
Opportunity
Solution
• Employ a condition-based, predictive maintenance model
• Minimize equipment downtime; reduction of 0.5% translates to up to $65,000 annually
• Reduce maintenance labor costs up to 20%; spare parts / material spend up to 30%
• Reduce total cost of ownership
Maximum uptime,reduced maintenance cost
Cloud-based event/fault detection
SECURED DATA
Asset model insights
Material Labor
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5
3
Automated maintenance planning
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Manufacturing facility running two 8-hour shifts, 6 days a week
Data collected from
controls and edge1
SENSORS
CONTROL NETWORK
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Pulse – Events
Collaboration
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Pulse – Trends
Increasing Motor
Vibration
Decreasing sorter rates Power consumption
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Asset Sentinel
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Asset Sentinel – Fault Tree
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Insight – Control Panel and Ambient Conditions
How efficiently is the system using power?
Power infeed quality +/- 5% Amperage draw – Should not increase
Temp – worker productivity/humidity – cardboard flow and weight
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Insight – Motor Temperature and Vibration
Vibration should be less than 0.4 IPS
Temp should be less than 150 °F
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• Graphical UI
• Historical data capture
STAGE 1
Visualization
• Trend analysis
• Predictive maintenance
• Optimization
• Mobile Alerts
STAGE 2
Insights
• Work orders and reporting
• Inventory optimization
• Labor optimization
STAGE 3
Automation Increase
Reliability
Improve
Utilization
and
Scalability
Maximize
Productivity
Deployment Stages
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Optimize balance of system at main merge and shipping
Value
Opportunity
• Increase output by 1% = 120 more cases, or $1,200K per hour
• Annually, increase site revenue by $6M
Utilization Improvement — Use Case for Distribution Centers 750k sq. ft. DC, operating 5,200 hours, 200 CPM rate
Solution
Data collected
from site
Maximum throughput
Cloud-based
SECURED DATA
Flow insights
1 2
5
3
Labor planning4PRODUCT & PEOPLE
MACHINE CONTROL
SECURED DATA
WES
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Analyze machine performance trends per SKU, identify barriers to palletizer productivity and quickly resolve issues
Value
Opportunity
• Unlock potential increases in run time and reduce idle time; improved utilization of 1% translates to $130,000 annually
• Monitor throughput targets
• Detect, trend and resolve error conditions
• Enhance root cause analysis and issue resolution for improved efficiencies
Utilization Improvement — Use Case for ManufacturingManufacturing facility with an average revenue of $2,600 per hour
Solution
Maximum throughput
Cloud-based
SECURED DATA
Flow insights
2
5
3
Utilization Monitoring4
SECURED DATA
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Insight – Production Monitor
Total carton counts for each day Rate of cartons being sorted
Daily productivity miss on Merge Lane 2 (symptom) Constant faults on Merge Lane 2 (root cause)
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This chart Indicates frequent sorter stops throughout each day
Insight – Production Monitor
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© C
opyright
Inte
llig
rate
d.
All r
ights
reserv
ed.
GoalPost® Labor Management System (LMS)
Standalone or combined with Momentum WES to provide full labor management and incentive
and performance pay solutions
• Reduces labor costs and increases throughput capacity
• Accurately and fairly calculates worker performance and incentives
• Dynamic, flexible reporting, analytics and dashboards
• Modules for resource time tracking, coaching, XYZ distance calculations and labor planning
• Easy to deploy and configure for fast ROI
• Current version installed in 40+ sites, product history has more that 150 installations
LMS measures, manages and plans warehouse labor for increased productivity, efficiency and performance.
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Dashboard HomepageDashboard provides current views into metric trends, overall performance and utilization. Visualizes information using beautiful, interactive charts that allow you to drill down and investigate areas without running a report.
Facility Level Metrics
Drill down to any
Department/Operation/Shift within the UI
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GoalPost calculates performance from engineered labor standards to provide accurate labor metrics that drive performance visibility.
• Performance calculations at all levels
• Flexible pay configurations
• Incentive pay curves
• User defined metrics
• Performance factors
Incentive and Performance calculations23
Performance factor equation builder
Pay curve example
Absence
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Time Tracking
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TimeKeeper is a time tracking solution that automates the manual processes related to tracking employees' time.
• Kiosk based time entry
• Enhances existing time solutions
• Filter and apply group actions
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Group transfer options
Electronic time capture
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Coaching and mentoring25
Coach is a coaching and mentoring tool for supervisors. Coach automatically identifies associates that need coaching, tracks the coaching sessions performed, displays performance data, and allows managers to view statistics by supervisor to evaluate coaching impact on performance.
• Flexible, user-defined coaching practices
• Automated identification of coaching candidates
• Track supervisor engagement
• Provides targeted feedback
Focused coaching
Coaching history
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LineUp Staff Planning26
LineUp Staff Planning empowers supervisors and managers to make effective
staffing decisions, both for daily labor allocation and long-term labor planning.
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Execution Dashboard27
LineUp Execution Monitoring allows operations to view in real-time how a plan
is executed and if resources should be added or removed in order to optimize
the labor involved.
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Reporting and Data Analysis28
GoalPost InSite delivers robust analytical reporting and mobile analytics for smartphones and tablets with more than 70 interactive reports that cover KPIs across all levels of the facility.
• Enterprise views of KPIs
• User customizable reports
• Wide depth of reporting topics
• Information mining
Reporting Levels Key Metrics Reporting Options
Enterprise Performance Dashboards
Facilities Utilization Interactive Reports
Departments Units per Hour Graphs
Shifts Cost per Unit Sorting/Filtering
Employees Efficiency PDF/Excel/CSV Export
Hours Direct Db Connections
Bonus Dollars
Quality
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InSite Dashboard Samples
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Use labor metrics to reduce warehouse attrition rates through predictive modeling of “at risk” behaviors
Value
Opportunity
• Bureau of Labor statistics estimates annual warehouse turnover to be 40%
Employee Turnover Reduction — Use Case 400 direct labor warehouse resources
Solution
Regression model uses historical
labor metrics to determine the
likelihood a resource will quit
Additional Value Drivers
• Ramp-up productivity
of new hires is typically
2–4 weeks
• Cost of reprocessing
errors impacts turnover
cost
• HR value for succession
planning and seasonal
hiring
• Cost impacts of new
hires who turn over
quickly and are replaced
Host system provides
activity data to LMS
WES * WMS * ERP * Vocollect
Resource Time Production
LMS Data Capture
LMS calculation engine
generates labor metrics
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2
3
4 Outputs graph of resources
grouped by risk of departure
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TechSight Overview
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Hands-free augmented reality
“See what I see” troubleshooting
Quickly diagnose critical issues
Reduction in required maintenance skills
Control system integration
Decrease unplanned downtime
Reduce costly travel for onsite experts
Subject Matter Expert access from anywhere
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TechSight User View
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Touch NavigationNavigate cards and select items with the
device’s touch controls.
Voice NavigationSpeak to navigate cards and select items.
Hands-FreeFollow voice direction while keeping two hands
available for a safe work environment.
Offline SupportApplications and data are cached offline so
work can be done without network connection.
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TechSight Expert Side
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TelestrationAnnotate on snapshots and
document snippets and synchronize
to smart glasses in real-time.
Document SharingClip and share snippets from PDF
documents directly to smart glasses.
HD Audio & VideoBi-directionally stream up to 720p HD
video and audio.
MessagingSend messages from Skylight Web
to smart glasses.
Remote ZoomRemotely zoom smart glasses.
Remote SnapshotsRemotely take snapshots from smart
glasses.
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CONNECTED DISTRIBUTION CENTER
END-TO-END EFFICIENCY
FROM OPERATION TO ENTERPRISE
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