planning and implementing your automation...

Presented by:

Mark Neuens

Planning and Implementing Your Automation

Needs

© 2016 MHI® Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved.

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



- 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


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


AS/RS

Palletizer x 3

FROM: Factory

Receiving

Store IN from factory

Store IN from outside warehouse

Material Flow


AS/RS

Floor Storage

Layer picker x 2

Shipping

Replenishment

Picking

Shipping OUT


1. Flexible system plan The number of machines in action can be adjusted based on system needs (RGV)


1. Flexible system plan

Manually Operated Area

RGV (Rail Guided Vehicle)

Manual Rack


2. Expansion plan

Expansion Line

Expansion AS/RS (Built 4 years after initial operation)


3. Back up plan For inbound from the production line


3. Back up plan For inbound from the outside


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


4. Good maintenance plan Monitoring system

Equipment

Monitoring system

Monitor

Alarm


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)

28

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

実証実験.mp4

29

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

http://www.storageandretrievalsystems.com/

http://www.storageandretrievalsystems.com/

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