OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
Applications of Sunstone RTLS in
logistic processes
Date created: 2019-02-18
Last modification: 2019-03-22
Author: Tamás Ruppert ( [Link]@[Link] )
1
OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
Contents:
1 Quick overview with recommendations: 3
2 Sunstone RTLS 4
3 Applications of Sunstone RTLS system in logistic processes: 5
3.1 Tracking pallets and stacks: 5
3.2 Tracking semi-finished goods 6
3.3 Monitoring stock, raw material 6
3.4 Forklift tracking 6
2
OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
1 Quick overview with recommendations
Transparency of logistic processes in production is an increasingly complex task.
Processing steps from the receipt of goods to managing inter-manufacturing stock and
finished products are critical. Any failure on these levels can result in high costs. The lack
of material, or even a critical high WIP level, can cause a significant short or long-term
loss. To make responsible decisions, logistics professionals need reliable information such
as stock levels and the current state of [Link] utilization and optimal distribution of
logistic transport vehicles (forklifts, trolleys) is also a critical task. Supporting them with
route advisory systems, enhancing and automating them with an intelligent calling system
can serve as additional optimization solution.
Basic logistical decisions (orders, production programming, resource/shift organization)
depend on the product line and warehouse inventories. Keeping this information up to date
is a cost and resource demanding task. Any additional inventory check and modification
(beyond essential steps) can be avoided by using a well-designed and reliable tracking
system.
3
OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
2 Sunstone RTLS
OMTLAB Ltd. has been developing Sunstone RTLS ( [Link] ) real-time
indoor positioning and data acquisition system for four years. Its customers are primarily
from the automotive and electronics industries, which optimize and automate their
processes by real-time tracking of tools in shopfloors and products under construction.
[Link]: The hardware elements of the Sunstone RTLS system in a manufacturing unit
Sunstone RTLS works as an “inverse” indoor GPS, which is capable of tracking and
collecting data in real-time from hundreds of active radio transmitters called TAGs. The
system requires to deploy receiver units called anchors at fixed points. Anchors are placed
along the edges of the area to be monitored (8 anchors per every 2000-3000m2). Anchor
units collect data packages sent by the TAGs with the time of arrival and forward it to the
central unit. Central unit forwards the data to a server (or cloud service), where current
TAG positions are calculated from the time of arrival with a few 10cm accuracies. The
calculated position and data is then stored and can be used for real-time and historical
data analysis.
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OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
[Link]: Product tracking within a factor unit using a Sunstone Mini-tag
3 Applications of Sunstone RTLS system in logistic
processes
3.1 Tracking pallets and stacks:
Finding pallets and stack is a common problem in raw material and finished goods
warehouses. This problem is especially true for warehouses, where finished products or
raw materials do not have a fixed allocation but are placed by arrival. Sunstone offers
three solutions:
- All pallets/stacks get linked to a TAG (pairing the stack ID with a TAG ID), the
system will know where to find the pallet/stack at any time.
- When only trolleys or a forklifts move the stacks, the position of the stack is
recorded by the system based on the movement of the transport vehicle. Identifying
the moving stack (scanner / RFID) is necessary. The advantage is that it’s sufficient
to track only the moving vehicles with the TAGs and not all the stacks. On the other
hand, if there are any non-tracked vehicles used for moving, the system will not be
able to provide proper information on products.
- It is also possible to track stacks with TAGs placed on scanners. When the stack is
placed its identifier must be scanned with a TAG-equipped scanner, then the
position of the scanner determines the location of the stack.
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OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
3.2 Tracking semi-finished goods
Pairing a semi-finished product with a TAG makes inter-manufacturing tracking possible.
Thus the following information is available:
- time spent on the working station for a given product
- the production sequence of the given product (between which stations it moved)
- which products are/have been on rework
- which products are/were in quality assurance
- average lead time for a particular product type (takt time)
The goods in production are available with a continuous, real-time production status that
supports production programming and shift design.
3.3 Monitoring stock, raw material
Typically, there are plenty of raw materials in the production, so it is convenient to identify
and track them in larger units (fewer TAGs). Identifying raw materials at palette level helps
to find them faster, the time spent of searching stocks and materials can be spared.
In the long run, analyzing of position data for raw materials can help to reduce and
optimize WIP and Kanban levels, and in combination with a well-designed inventory
system, discrepancies and inventory checking frequencies can be reduced.
3.4 Forklift tracking
Tracking logistical transport vehicles (mainly forklift, trolley) in warehouses and halls,
makes the following reports available:
- Analyzing movements: vehicle routes, time spent in specific areas, speed.
Evaluating data development proposals can be made.
- Optimal route planning with an interactive display
- Provides data for predictive maintenance
- Forklift OEE (Overall equipment effectiveness) calculation
6
OMTLAB Ltd.
info@[Link]
Applications of Sunstone RTLS
in logistic processes
In addition to position data, Sunstone TAGs allow collecting additional sensor data and
real-time transfer directly from the forklift. These are typically fork load, seat usage,
fuel/battery level, maintenance information.