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Case Study © by Ubisense 20092

BMW Car Plant Regensburg, Germany BMW Car Plant Regensburg, Germany (Final Assembly Tool (Final Assembly Tool Assistance)Assistance)

Installed area: 1.7 km assembly line | Sensors: 350 | Accuracy: 30 cm in 3D | Events/day: 150000 | Reliability: Installed area: 1.7 km assembly line | Sensors: 350 | Accuracy: 30 cm in 3D | Events/day: 150000 | Reliability: 99.99%99.99%

Production Management System

Production Management System

DC Tooling

Ubisense Tool

Assistance

Ubisense Tool

Assistance

IBS Tool Controlle

r

IBS Tool Controlle

r

Vehicle - Tool association

Manufacturing

Reference Customer

ProblemDifferent models of car are produced on the same line necessitating loading a different tool program into the power tools based on the specific vehicle to be worked upon. Previously the identification of the vehicle occurred using a barcode scanner resulting in unproductive work (~6 seconds per tool op. at 150 tool stations on 1,000 cars per day).

The Ubisense solutionThe Ubisense system tracks both vehicles and tools detecting when a tool is brought close to the vehicle. The required tool program is obtained from the MES using the VIN and sent directly to the IBS Tool Controller to program & enable the tool. The system solution was jointly developed by Ubisense and IBS.

ResultCost and time reduction on the line and quality improvement by excluding human error and re-work. Unproductive time saved reduces costs by many $100,000‘s.



OtherLogistics


Aston Martin Car Plant Gaydon, UK Aston Martin Car Plant Gaydon, UK (Finishing Process Tracking)(Finishing Process Tracking)

Installed area: 11700 m² | Sensors: 58 | Accuracy: 50 cm in 2D | Reliability: 99.9%Installed area: 11700 m² | Sensors: 58 | Accuracy: 50 cm in 2D | Reliability: 99.9%

Enterprise IntranetEnterprise Intranet

Ubisense Process Tracker


Vehicle - Bay /Area association &

process rules

Manufacturing

ProblemAs cars come off-line into the finishing area, they can miss process steps leading to rework or become ‘stuck’ in a step creating inventory build up.

The Ubisense solutionThe Ubisense system tracks the vehicles as they come ‘off-line’ and move through specific process stages (rolling road, wheel alignment, paint inspection, etc.). Defined rules specify the process order and dwell time thresholds (time spent in a step). Exceptions trigger alerts visible to shop-floor operators and reported on intranet.

ResultTime reduction and Work In Progress (WIP) throughput improvement as cars are always visible through the finish and rework process. Reduced rework and improved quality.



OtherLogistics


Honda Motorcycle Plant Atessa, Italia Honda Motorcycle Plant Atessa, Italia (Component Process (Component Process Tracking)Tracking)

Library Images

Installed area: 2000 m² (75 m assembly line) | Sensors: 13 | Accuracy: 30 cm in 3D | Reliability: 99.9%Installed area: 2000 m² (75 m assembly line) | Sensors: 13 | Accuracy: 30 cm in 3D | Reliability: 99.9%

IBM LASIBM LAS

Frame Identification

Ubisense Location Platform


Passive RFID

Passive RFID

Motorcycle & Components

Tracking

Manufacturing

ProblemThe production process required manual barcode scanning of printed VIN labels at each station in order to call up the specific task list. In addition, there was no traceability of major components.

The Ubisense solutionThe Ubisense system tracks vehicles on the line enabling automatic identification of required tasks at each station (via interface with Production Planning System). In addition, major components are tracked and associated with specific vehicle to provide automatic traceability and replenishment signaling.

ResultProcess optimization and error reduction on the line has increased productivity and quality. In addition inventory replenishment has been improved and component traceability means long term quality and customer satisfaction will be improved.



OtherLogistics


Ortrander Iron Foundry Ortrand, Germany Ortrander Iron Foundry Ortrand, Germany (Material Flow (Material Flow Tracking)Tracking)


Ortrander PPSOrtrander PPS

Material Identification &

Weighing



Passive RFID & Weighing

Sys.

Passive RFID & Weighing

Sys.

Forklift Tracking

Manufacturing

ProblemThe content (number and type of part, status in production cycle) and location of containers was not visible centrally in the production control system. This resulted in delays fulfilling customer orders since it was not known whether or not sufficient quantities of completed parts were available.

The Ubisense solutionThe Ubisense RTLS continuously tracks forklift movements whilst the Spatial Platform maps processing stations and storage locations as hot-zones and combines these with the pallet ID determined via passive RFID reader and the results of the on-fork weighing system. As pallets are slotted the PPS is informed, so it knows the specific ID and location of pallets at all times and can update the process stages of orders automatically in real-time.

ResultIncreased productivity, reduced cost & dwell time, faster fulfillment of customer orders.



OtherLogistics


Caterpillar Equipment Plant Gosselies, Belgium Caterpillar Equipment Plant Gosselies, Belgium (Assembly Tool (Assembly Tool Control)Control)

Manufacturing

DeJaeger Protrac (PMS)DeJaeger Protrac (PMS)

DC Tooling



DeJaeger Tool

Control

DeJaeger Tool

Control

Valve - Tool association


ProblemThe assembly of the hydraulic valves at the heart of Caterpillar construction vehicles is performed using torque wrenches to fasten reinforced tube hoses to the valves. The tightening of a bolt that fastens a hose to a valve must be applied with a specific amount of torque – around 300 Newton meters (Nm) – in order for that valve to operate properly. Caterpillar’s quality standards demand 100% traceability of correctly tightened hoses.

The Ubisense solutionThe Ubisense system tracks wireless electronic wrenches, detecting when the tool is brought close a valve assembly station. Each wrench is designated for a specific assembly station, and is preset to tighten a specified amount. The location information ensures that each wrench is being used at the correct station when the quality data is collected.

ResultIncrease in correctly assembled valves and hoses leading to less rework on leaking valves.



OtherLogistics


ProblemFinding / tracking assets and tools on the dock and inside buildings. Assisting in the completion of audits for government owned equipment

The Ubisense SolutionLong range sensors tracking tagged assets between ships. Combination of wired and wireless sensors working indoors and outside in very harsh conditions

Accuracy delivered 1 – 1,5m

ResultsImprove efficiency by reducing search times. Improve production times and reduce time to complete government audits

Bath Iron Works Shipyard Maine, USABath Iron Works Shipyard Maine, USA (Asset Management)(Asset Management)

Manufacturing

Installed area: xxx m² | Sensors: 54 | Accuracy: 100 cm in 3DInstalled area: xxx m² | Sensors: 54 | Accuracy: 100 cm in 3D


Ubisense Asset TrackerUbisense

Asset Tracker

Asset & Tool Tracking



OtherLogistics


Cummins Engine Plant Jamestown, USA Cummins Engine Plant Jamestown, USA (Test Process Monitoring)(Test Process Monitoring)

Manufacturing

Installed area: xxx m² | Sensors: 76 | Accuracy: 30 cm in 3D | Reliability: 99.9%Installed area: xxx m² | Sensors: 76 | Accuracy: 30 cm in 3D | Reliability: 99.9%

Allen-Bradley PLCAllen-Bradley PLC



Engine - Bay /Area association &

process rules

ProblemSearching for engines throughout the repair, test and shipping areas was taking too long and slowing down production cycle time and requiring extra staff.

The Ubisense SolutionTags are scanned, associated with and attached to engines as they enter the repair or shipping areas. Engines then are tracked and every time an engine enters or exits a work cell the exact time is recorded in a standard database and passed into the Allen-Bradley PLC. In addition their location can be determined via a web browser.

As engines leave the plant, tags are removed in the shipping office and automatically disassociated from the engines they had been attached to.

ResultContinuous automated monitoring processes leading to higher throughput. Search time for engines has dramatically decreased (in the repair area search time has decreased by 98%)



OtherLogistics


SMDK Kölliken, SwitzerlandSMDK Kölliken, Switzerland (Personnel Security)(Personnel Security)

Personnel Tracking



Installed area: 11000 m² in phase 1 | Sensors: 42 | Accuracy: 100 cm in 3DInstalled area: 11000 m² in phase 1 | Sensors: 42 | Accuracy: 100 cm in 3D

Process & Energy

ProblemAt the toxic waste dump in Kölliken (SMDK), chemicals are leaking into the groundwater and threatening the drinking water supply. Therefore the local government ordered the complete dismantling of the dump which is being carried out in 2 phases. As contaminated materials are removed, a “black” area had to be erected, consisting of a hall preventing the escape of toxic dust, gas and odours. Worker safety is a primary concern and escape tunnels proved impractical for both engineering as well as cost reasons.

The Ubisense SolutionEach worker wears a Ubisense Tag on their helmet. The tracking system enables the Arge Phoenix management to know the precise whereabouts of all workers within the site's "black" areas so it can maintain a precise head count in case of a fire or other emergency, and rescue any employees having difficulty escaping to safety.

ResultsGreatly improved worker safety in the “black” area.



OtherLogistics


Areva NP Archive Erlangen, GermanyAreva NP Archive Erlangen, Germany (Personnel Security)(Personnel Security)

Installed area: 1800 m² divided up into several rooms | Sensors: 34 | Accuracy: 100 cm in 2DInstalled area: 1800 m² divided up into several rooms | Sensors: 34 | Accuracy: 100 cm in 2D

Process & Energy

Reference Customer

Personnel Tracking



(1) Automated Alarm(2) Manual Alarm(3) Alarm System(4) Acoustic Equipment(5) Optical Equipment(6) Gas Container(7) Nozzles

ProblemPlans and related building documents for nuclear reactors are stored in the Areva NP central archive for up to 90 years in acc. with government regulations related to nuclear facilities. In order to prevent loss or damage from the use of conventional extinguishers, a system is installed which floods the archive with nitrogen in case of fire. In such a situation, it is imperative to be able to immediately locate all personnel currently in the archive precisely and reliably to facilitate rapid rescue and evacuation.

The Ubisense SolutionVisitors and employees are registered and supplied with a Ubisense tag upon entry into the archive. The integrated Ubisense 3D Visualization provides a graphical indication of where the personnel are at all times. In addition an associated list is maintained, displaying in real-time exactly in which areas how many staff are located.

ResultsGreatly improved worker safety in the archive.



OtherLogistics


BNFL Nuclear Power Facility Sellafield, UKBNFL Nuclear Power Facility Sellafield, UK (Personnel Security)(Personnel Security)

BIL SolutionsBIL Solutions

Personnel Tracking



Installed area: 100 m² | Sensors: 8 | Accuracy: 30 cm in 3DInstalled area: 100 m² | Sensors: 8 | Accuracy: 30 cm in 3D

Process & Energy

Reference Customer

Radiation Measurements

Radiation DosimetersRadiation

Dosimeters

ProblemSellafield is one of 20 aging U.K. nuclear facilities being decommissioned. Employees involved in decommissioning and clean-up within the facility are exposed to fluctuating radiation. It is vital to ensure that the amount of radiation to which they are exposed during any one work period remains below the specified limits.

The Ubisense SolutionEmployees carrying out work assignments at the power plant wear both Ubisense Tags and WiFi dosimeters, which measure radiation levels. BIL Solutions' software provides views of the facility, with radiation levels depicted in different colors combining location data from the Ubisense RTLS with the radiation readings. Workers' dose histories are monitored real-time as an aid to scheduling their work in the plant.

ResultsThe radiation maps and real-time exposure records significantly improve worker safety and efficiency of the operation.



OtherLogistics


BP Refinery, Germany BP Refinery, Germany (Personnel Safety Pilot Installation)(Personnel Safety Pilot Installation)

Process & Energy

Installed area: Perimeter around 22000 m² | Sensors: 22 | Accuracy: 150 cm in 2DInstalled area: Perimeter around 22000 m² | Sensors: 22 | Accuracy: 150 cm in 2D

Personnel Tracking and Identification



ProblemSafety monitoring of personnel in hazardous environments.

The Ubisense solutionThe Ubisense RTLS network covers the perimeter, access paths and strategic internal junctions and tracks staff wearing tags on their helmets as they walk around the enclosed area. The Spatial Platform creates hot zones around hazardous plant to provide visual safety alerts.

ResultReal time location visibility and zone-level monitoring of personnel

Automatic notification of unauthorised entry into safety critical zones

Increased safety and process compliance



OtherLogistics


VBL Bus Depot Luzern, SwitzerlandVBL Bus Depot Luzern, Switzerland (Depot Management)(Depot Management)

Installed area: 15000 m² in 1 depot | Sensors: 48 | Accuracy: 100 cm in 2D | Reliability: 99.9%Installed area: 15000 m² in 1 depot | Sensors: 48 | Accuracy: 100 cm in 2D | Reliability: 99.9%

Swiss Axis BeDipsSwiss Axis BeDips

Bus Tracking and Identification



Public Transport

Reference Customer

ProblemManagement of the workflow in a bus-depot is an important issue today. Knowing, if a bus enters or leaves a depot as well as the position of the each bus inside a depot is fundamental for efficient planning and dispatching.

The Ubisense SolutionEach of the 160 buses of vbl is tagged, allowing the Ubisense platform to determine time stamps of incoming and outgoing buses and an exact bay, lane, and position of each bus, as soon as it is parked inside the garage. The online-interface to the Swiss Axis BeDips Depot Management System enables dispatchers to efficiently schedule and organise the parking, maintenance and refuelling processes in the depot.

ResultsCorrect, fast and reliable dispatching, correct invoicing of the work in a depot (maintenance, cleaning and preparation for the daily use)



OtherLogistics


JeNah Bus & Tram Depots Jena, Germany JeNah Bus & Tram Depots Jena, Germany (Depot Management)(Depot Management)

Public Transport

VAB Depot Management System

VAB Depot Management System

Bus and TramTracking and Identification



Installed area: xxx m² over 2 depots | Sensors: 104 | Accuracy: 100 cm in 2D | Reliability: 99.9%Installed area: xxx m² over 2 depots | Sensors: 104 | Accuracy: 100 cm in 2D | Reliability: 99.9%

ProblemManagement of the workflow in tram and bus depots is an important issue today. Knowing, if a vehicle enters or leaves a depot as well as the position of the each vehicle inside the depots is fundamental for correct dispatching, maintenance planning and invoicing.

The Ubisense SolutionEach of the 40 trams and 135 buses of JeNah is tagged allowing the Ubisense platform to determine time stamps of incoming and outgoing vehicles and an exact bay, lane, and position of each vehicle, as soon as it is parked in- or outdoors in one of the depots. The online-interface to the Depot Management System of Verkehrsautomatisierung Berlin (VAB) enables the dispatchers to take better decisions and operate more efficiently.

ResultsCorrect, fast and reliable dispatching, correct invoicing of the work in a depot (maintenance, cleaning and preparation for the daily use)



OtherLogistics


Metro Transit Bus Depots Minneapolis, USAMetro Transit Bus Depots Minneapolis, USA (Transit Yard (Transit Yard Management)Management)

Installed area: xxx m² over 5 garages | Sensors: 450 | Accuracy: 100 cm in 2D | Reliability: 99.9%Installed area: xxx m² over 5 garages | Sensors: 450 | Accuracy: 100 cm in 2D | Reliability: 99.9%

Bus Tracking and Identification


Ubisense Transit Yard

Manager

Ubisense Transit Yard

Manager

Public Transport

Reference Customer

ProblemBuses were being manually located and their location input into the Scheduling and Dispatching System using a paper mark-up sheet which was never up to date.

The Ubisense SolutionEach bus of the 1000 buses of Metro Transit is tagged allowing the Ubisense platform to determine an exact bay, lane, and position of each bus, as soon as it is parked inside the garage and in some outdoor areas. Dispatchers have real time visualization of vehicles for assignment.

ResultsElimination of need for dedicated search personnel in each of the five Metro Transit garages.

Faster and more reliable information about bus location

Assistance in determining bus departure and arrival times and time spent in maintenance



OtherLogistics


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