Location-aware optimisation of manufacturing processes
Manufacturing of the cutting-edge, specialised high-tech production automation and advanced systems products of AAE is organised and optimised with the help of the INDUTRAX application PRODUCTTRACKER and real-time indoor location tracking in conjunction with the enterprise production planning and control system.
Background
Specialising in producing advanced high-tech machinery, AAE caters to machine manufacturers in the medical, pharmaceutical, automotive, consumer goods, semiconductor, solar, and food industries. To fit the needs of their varying customer base, manufacturing their high-tech products is done in a build-to-order approach with batch quantities ranging down to one.
Challenge
Optimised production planning is a time-consuming daily challenge. This is due to over 1000 active orders at any time, all in different stages of production and involving numerous processing steps inside and outside the cleanrooms with variable routing, as well as the involvement of subcontractors. The main goal was to maintain an overview of the processes, taking into account all influencing factors while prioritising efficiency.
The location-aware solution
AAE has implemented a digital solution to enable all orders in production to be tracked and monitored automatically based on the INDUTRAX application PRODUCTTRACKER in interaction with the production planning and control system ISAH ERP as well as real-time location data from the Quuppa Intelligent Positioning System.
Indutrax application
AAE has successfully implemented a solution, and the automated tracking of all orders is now made possible. In collaboration with the ISAH ERP production planning and control system and real-time locating system (RTLS) technology from the Quuppa Intelligent Positioning system, this digital solution was found based on the INDUTRAX location-aware application PRODUCTTRACKER.
Transparency in process status and whereabouts of orders is enabled through the INDUTRAX PRODUCTTRACKER. Implementing a digital shadow of the factory allows for reliable data on execution events to be created in real time. As many as 2,500 production orders are tracked simultaneously indoors by the Quuppa real-time location system using Quuppa-certified Bluetooth® Tags from BlueUp. The logging and storing of these daily production order movements are used to generate pattern-based reports. In turn, these pattern-based reports serve as a reference for business analytics and allow for schedule-based production planning to be imposed.
The location data retrieved from the Quuppa system is processed by INDUTRAX Software Core Services, which precisely monitors and records the events executed in daily operations and stores these events in a database. The recorded events can be viewed in report format to view the production comprehensively from start to finish. This also makes identifying and troubleshooting idle times and bottlenecks possible and can, therefore, further optimise production flow.
With this solution, the following factors are enabled:
- Automatic update of order locations
- Automatic recording of work in progress and inventory
- Determining idle times in the process
- Automatic recording of movements
- Planned vs. actual process flow comparison
- Lean reports.
Benefits
Production transparency achieved through locating technology allows for increased productivity in daily operations. Through an improved overview of order status, individual order tracking capabilities, and faster response times to delays, AAE is equipped to optimise their productivity while reducing costs.
This infrastructure, allowing new insights to come to light, has further facilitated productivity, significantly reducing non-value-added activity. Satisfied with the solutions tracking capabilities offer, AAE’s future expansion activities will certainly involve locating technology.
Outlook
The location-aware solutions are a critical element of AAE’s digital transformation journey. More and more insights come to light that are used for continuous improvement processes. AAE is looking to expand its facilities further with a new building, and the INDUTRAX location-aware solution will undoubtedly be an integral part.