Improving operational efficiency in a sorting center is always front of mind for managers, but it can often be challenging. At PostNord’s Hakkila terminal in Finland, for example, management faced challenges when trying to optimize the facility’s sorting processes.

The terminal had problems maintaining operational quality, due to site design, fluctuating volumes and changing management and processes. There was also a lack of oversight of resource use and process compliance, and an inability to measure performance.

“The terminal was fairly new but had become congested quickly due to the volumes coming in,” explains Christian Østergaard, PostNord’s lead visionary and senior group strategist. “They had just gone through their first peak, which management felt had been quite disorganized and inefficient, so they reached out to our team to see how we might help them address issues around productivity, throughput and efficiency.”

The timing couldn’t have been better for Østergaard and his colleagues as they had something new they wanted to trial: a digital thread sorting solution.

”WE WANTED TO BE ABLE TO MONITOR ALL OUR INTERNAL PROCESSES AND TO SEE WHERE OUR WORKERS WERE, TO SEE IF THE PROCESSES WERE OPTIMAL”

Christian Østergaard, PostNord

When looking to improve operational efficiency, the focus is often on working out which of the many sorter and process flow configurations is optimal for a specific facility. However, what is regularly overlooked is improving visibility across the site – of everything from execution flows and resource allocation through to movements and internal transportation.

Most managers won’t have access to such information, which means decisions are often based on personal experience or a ‘gut feeling’, and will differ from leader to leader. Being in constant operational mode also limits managers’ ability to think about these details, which is why PostNord wanted to trial this new solution, which would introduce more data-driven ways of working and just-in-time thinking.

Digital thread sorting solution

PostNord’s digital thread sorting solution creates a real-time representation of the entire sorting center across all assets and moving parts, thereby improving the understanding of process flows.

LEFT: The digital thread sorting solution uses a real-time location system to ensure workers are in the optimal place.

RIGHT: The solution enables PostNord staff to quickly identify areas of concern within the sorting machines

It is the result of several technology projects across the organization that Østergaard and his colleagues realized could be amalgamated and developed into an overarching sorting solution.

“The idea was to use computer vision together with a real-time location system (RTLS),” Østergaard explains. “Putting sensors in different places across the terminal would enable us to collect data in real time. We wanted to be able to monitor all our internal processes and to see where our workers were, to see if the processes were optimal or whether there was room for improvement.”

Digital thread benefits

• An operational efficiency gain of more than 25% in sorting operations
• A 32% increase in the number of parcels sorted per hour
• Percentage of sorting staff meeting KPIs has risen from 20% to 54%
• ROI of technology pilot was less than four months

Gaining trust

The rollout of the digital thread sorting solution took place in stages, working in close collaboration with the local management team.

“When you come in with a new technology, it’s important to gain the trust of the people who will use it. We had a list of the things we wanted to do but began by asking them if they had specific problems that they wanted us to look at,” Østergaard reports.

“They raised two areas of concern: an underperforming machine and making sure the first-in, first-out principle was being used when it came to storage. For the first issue, we were quickly able to establish functions that enabled staff to see what was going wrong in the process, so it could be resolved. For the second, we visualized things for them, so they could see what was happening. This built the trust and it then became a question of okay, how do we go ahead and roll out everything else?”

At each stage of the rollout, solutions were reviewed and tweaked if necessary. “It was a great collaboration, where there was the strategic team looking at how we can get the technology to work, our partner vendors, who were focused on making it work, and the local tech-savvy management, who were keen to use technology to improve efficiencies,” comments Ravi Kiran Kotty, digital transformation technology strategist at PostNord.

“They’d say, ‘Okay, we think we can be more efficient here’, and we’d sit down and come up with a solution. If the first iteration didn’t work exactly as they wanted, then we reconfigured it so that it was fit for their purpose.

“It was a slow evolution,” Kotty continues. “We went use case by use case. Once it was implemented, we would evaluate whether it added value before moving on to the next one. We’d identify an asset, try to generate data from it, then the value, before looking to add additional assets. There was no big bang, it was a progressive thing, which added value exponentially with every use case.”

”EVERYONE LIKES SIMPLICITY. THEY DON’T WANT A LOT OF DATA, JUST QUICK ANSWERS OR SIMPLIFIED GUIDANCE”

Ravi Kiran Kotty, PostNord

A collaborative partnership

After launching its new sorting facility in September 2022, PostNord faced challenges with productivity KPIs such as parcel throughput and production efficiency. The need for reliable tracking and monitoring led to the implementation of Quuppa’s RTLS technology. By tracking mobile devices and forklifts, PostNord gained real-time visibility of transportation movements and resource allocation, especially in critical areas like sorting machines and cross-docking zones. This visibility allowed for the identification of process inefficiencies, enabling optimization of workflows.

The collected KPIs and analytics are computed in near real time and provided directly to the relevant people within the facility, allowing PostNord to optimize work floor and sorting chute handling, monitor the number of trips between overflow chutes and improve the use of the cross-docking areas. These improvements have resulted in a more than 20% increase in efficiency and productivity.

The technology also enables data-driven decision-making, moving away from guesswork to fact-based planning. Real-time insights allowed better resource allocation and shift planning, improving operational processes and reducing internal lead times. This shift has helped PostNord to achieve higher delivery quality and improve parcel throughput.

By integrating the system into a digital twin model, PostNord has advanced toward its 2032 vision of touchless parcel handling, improving both operational efficiency and sustainability.

PostNord partnered with two key vendors on the development of the digital thread solution: Tata Consultancy Services (TCS) and Quuppa. TCS helped the post build its computer vision models, while Finnish startup Quuppa provided high-precision indoor tracking technology.

Work on the project began back in May 2023, with the digital thread solution completed by the end of January 2024. The biggest integration of new technology into the terminal was the installation of Quuppa’s RTLS technology. This entailed a full site survey to assess what was needed in terms of physical infrastructure.

“The first part was installation, which took some time, but after that we were able to deliver new use cases every couple of weeks,” Kotty notes.

ABOVE: The solution provides a real-time overview of parcel volumes.

LEFT: A spaghetti diagram of internal transportation volume in the sorting terminal.

One of the first use cases was employing PostNord’s existing security camera system to monitor movements and processes, to identify areas of concern. “The good thing with computer vision is that if you already have the cameras, you just need to introduce an ‘intelligent filter’ that is trained in what to identify and measure,” says Østergaard.

Improving visibility

PostNord says the digital thread is helping to measure two key areas: productivity and internal transportation. Productivity is assessed in an anonymized way, examining processes and supporting functions using existing handheld devices.

“We don’t want to know who each worker is – we simply want to know where people are and what they are doing at any given time. We ‘Smurf’ them, because our system shows them as blue,” Østergaard chuckles.

This enables management to see whether the site or workflow is designed in a way that adds leakage. They can also evaluate different processes and identify any wasted productivity and the reason behind it.

In terms of internal transportation, visualization, control points, flow optimization and new data help PostNord achieve better use of assets like forklifts, employees and floor space.

Benefits to all

The digital thread benefits all levels of staff, from those on the shop floor through to shift leaders and process designers. The business case has already been proved at Hakkila, where the terminal has seen a more than 25% increase in operational efficiency in sorting, in addition to increased productivity, improved quality, the removal of bottlenecks and the establishment of performance measurement.

“We regularly check in with the Hakkila team and each time we speak they’ve consistently improved,” enthuses Kotty.

“That’s possible because we’ve created a ‘blue ocean’ of data; some that had never been looked at before,” Østergaard adds.

A standout use case at Hakkila has been the introduction of a simple traffic light system to communicate needs to terminal staff. PostNord has a staff turnover of 8% a month in this specific terminal, so it needed something straightforward and self-explanatory that everyone could understand straight away. It therefore introduced a visual tool where screens show areas of the facility as green (low attention), yellow (high attention) or red (critical) to let staff easily see where they’re needed. “If they see a red or yellow area on the screen, they know they can be useful there. This visualization enables them to make better use of themselves without the need for management to intervene,” continues Østergaard.

By giving staff continuous information on where they were most needed, the number of parcels they could handle per hour increased by almost 30%, notes Kotty. In addition, before the introduction of the traffic light tool, only 20% of those on the floor were able to meet the KPI targets PostNord had set – now 54% can. “They’re able to work more efficiently,” he enthuses.

ABOVE: A traffic light visual tool ensures the system is easy for new staff to understand

Modern image

The introduction of the digital thread has had a positive impact on the company’s image, with many employees saying that they regard PostNord as a modern employer.

“Many of our employees are gamers; they have a vacuum cleaner robot at home; they’re tech savvy and have an expectation that their employer will be too.

So it’s been very positive for the company’s brand,” explains Østergaard. “It’s also easier to teach people new functions.”

“Indeed, we always want to trust simplicity rules, and this project helped us validate that,” notes Kotty. “Everyone likes simplicity. They don’t want a lot of data, just quick answers or simplified guidance.

“The ROI is between three and four months, again validating this as a good approach to take. Of course, there are a couple of prerequisites: you need an organization that’s tech savvy, and people who are open to change and will support your implementation. But there are not many use cases where you can see productivity increases of this ratio, with this kind of payback.”

What lessons has POSTNORD learned?

• Tech-savvy local management and workers are key to implementing and adopting new technology in operations
• You can make use of lots of your existing infrastructure to gain new insights into how your processes are running
• Collaboration between all parties is essential
• Keep communication of data simple and straightforward

Next steps

Next steps The development of the digital thread is an important step toward hyper-automation of PostNord’s terminal operating execution model. The post says it’s been a perfect playing field for operations, innovation and IT to evaluate and implement the right changes and at the right time.

It plans to continue bringing many of its use cases together as part of the digital thread, including asset tracking, forecasting and digital twins.

Based on the success at Hakkila, PostNord is now rolling out the digital thread solution in Denmark. Once the first site has been successfully completed, the plan is to scale it to the country’s two largest terminals.

This Case Study was originally published on Parceland Postal Technology International

The post Case Study: Real-Time Visibility at PostNord appeared first on Quuppa.

Think of RTLS as the GPS of the industrial world, providing insights into the movement and location of equipment and assets, tracking everything from forklifts to shipping containers to consumer goods, indoors and outdoors. But instead of solely capturing asset coordinates, modern RTLS systems offer displays to communicate asset information in real time, showing where an asset has been and where it needs to go.

I’d like to explain more about data visualization with RTLS—and what problems can be overcome using it—with what I imagine is the next biggest trend in industrial logistics.

How To Visualize Data

While the visualization of location data in logistics is still in its early stages, digital displays tied to real-time information are already the norm in other vertical markets. Consider the recent adoption of electronic shelf labels (ESLs) in retail spaces, particularly at grocery stores. Food products are marked with digital labels to accurately reflect the unit price, daily discounts and stock availability, along with other relevant product information.

With the advent of ESLs, we’ve seen a major shift away from paper toward digital price tags; generally, these displays are more sustainable and less resource-intensive to maintain and operate.

But what’s the relevance of these displays to manufacturing? Mostly, data visualization tools enhance industrial RTLS projects by providing instructions in an easily accessible format and improving process flow.

Such instruction can be achieved by attaching digital displays to transport units—whether it’s a box, roller cage or palette—to reveal dynamic real-time information on asset storage and movement. For example, if an employee takes a forklift of boxes to the wrong location in a warehouse or on a factory floor, the display on the forklift, or the display directly mounted on the boxes, will change the text in real time to say “wrong destination, take me to this location instead.”

A more simplified example of this is pick-to-light technology: If an employee comes close to something they should grab, the display blinks at them. Digital location displays don’t necessarily have to display text, they can also be scannable barcodes or QR-codes that are displayed and dynamically updated or have a blinking LED light.

Why Visualize Data

With this advanced RTLS system in place, employees on the operations floor receive immediate dynamic feedback on whether they’re executing the right process or completing the right task. This all brings direct benefits to process optimization, reducing search time and minimizing human errors. Overall, a display tag guides an employee’s immediate actions to improve process flow across a facility.

Digital displays can also be leveraged to improve inventory management. By using electronic tags and displays, manufacturing plants and warehouses can track goods at every stage of the production process, both on the backend postal applications, as well as directly from the facility floor. Digital displays provide real-time information on inventory levels, locations and movements, ensuring resources are used efficiently and reducing the need for overstocking and waste.

Data visualization may also play a crucial role in improving sustainability along the supply chain. By tracking the movement of goods in real time, logistics providers can identify opportunities to reduce waste and optimize resource usage. Moreover, digital displays also reduce paper waste and related inefficiencies. Instead of constantly changing paper tags as asset information changes, the tag remains the same but the information displayed on it transforms.

Challenges To Implementation

While RTLS coupled with digital displays offers significant benefits, their implementation isn’t without challenges. Understanding and addressing these concerns is essential for a successful deployment.

For one, implementing RTLS requires substantial investment in both technology and facility modernization. Many companies aspire to achieve digitization, Industry 4.0 standards, sustainability and reduced CO2 footprints. However, realizing these benefits necessitates upgrading infrastructure, which can be costly and time-consuming. Organizations need to carefully assess their readiness for such investments and plan for gradual integration to manage costs effectively.

Facilities also need to be prepared to analyze and leverage large amounts of data. RTLS generates vast amounts of data and insights into process flows, which can be overwhelming if not managed properly.

The key to leveraging this data is integrating it into existing processes and adapting performance metrics and reporting mechanisms accordingly. Organizations must establish robust data analysis frameworks and be prepared to act on the insights provided by RTLS. This requires a top-down mandate to drive change across the organization.

However, such mandates may not be well received. Introducing RTLS and digital displays in an industrial environment may meet resistance from employees who are accustomed to existing processes. Workers may feel that their knowledge and expertise are being undervalued. This mindset can create friction when new technologies are introduced.

However, it’s crucial to communicate that RTLS is not about replacing the workforce but enhancing their efficiency and streamlining their workflow.

Moving Forward

The integration of digital displays with RTLS is part of a wider global trend shifting away from static paper labels with outdated information to smart displays with dynamic information.

In logistics, that means asset information—be it product specs, expiration or shipping information—is clearly displayed with an asset anywhere in the facility. The goal is to optimize the process while minimizing unnecessary costs and efficiencies

In essence, this advancement enables the right information to be in the right place at the right time. That’s what RTLS is all about.

This article was originally published on Forbes.com.

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For this reason, the French freight forwarding company DGS Transports sought a suitable solution to track goods in their 6,000 square metre cross dock conveniently, quickly, and reliably. Having heard about DIVIS through its German partner companies in the CargoLine general cargo network, DGS Transports opted for its CargoVIS video management solution paired with the Location+ feature module, an indoor positioning system powered by DIVIS partner Quuppa. Consequently, DIVIS’s video management system (VMS) is not only used by many French customers in the parcel industry but also increasingly in the French cargo market.

Highest level of quality and service for customers

Software-based video management systems offer valuable services in the forwarding industry, and seamless consignment tracking has become an integral part of everyday logistics. Precise indoor positioning is crucial in this context.

Not only can the quality of service be significantly increased, but the flow of information can also become more transparent with the help of shipment tracking. Consequently, customer inquiries can be answered quickly and reliably, and even rare discrepancies can be clearly traced in the shortest possible time thanks to the system.

Our decision to opt for a visual consignment tracking system with indoor positioning is closely linked to our objectives in terms of quality and customer service. We needed a solution that was easy for our employees to learn and, at the same time, extremely efficient in terms of time expenditure. The advantage of indoor tracking is that we can locate all goods as quickly as possible and monitor their movements.”

Ludovic Charlec, Chief Operations Officer at DGS Transports

Achieving precise shipment tracking with a seamless movement path

DGS Transports uses the CargoVIS video management solution with indoor positioning powered by Quuppa. Sixty cameras record every movement of goods within the cross-dock. This innovative VMS replaces time-consuming conventional shipment tracking in the cross-dock.

The intuitive video management software offers image-based tracking, allowing palletised shipments to be traced and quickly located. Even if a shipment has already left the cross-dock, its path can still be traced afterwards thanks to CargoVIS’s use of video recordings. Uncertainties regarding transfers of liability and missing shipments are now a thing of the past. With the VMS, critical points can be reliably documented, and losses can be reduced.

Shipment tracking in CargoVIS

• By automatically linking shipment data from the transport management system with image data, each shipment leaves its individual fingerprint in CargoVIS with every scan.
• As the shipment passes through the hall, a movement path of information is created, enabling the goods to be tracked specifically and precisely in the cross-dock via scan times – by entering the shipment or pallet number.

Indoor positioning with Location+ is comparable to outdoor satellite-controlled GPS, but more precise methods are required indoors. While GPS relies on coded radio signals from orbiting satellites for outdoor tracking, indoor environments demand more refined methods. Bluetooth® is often used for indoor shipment positioning, with Quuppa Intelligent Locating System® standing out as one of the most reliable methods for enclosed areas and offering many advantages for logistics. Here, infrastructure devices known as Locators replicate satellite functions, while Bluetooth® application on scanners acts as GPS receivers. This method ensures accurate scanning processes with an impressive accuracy of up to 50 cm.

Thanks to the combination of location data, scan data and recorded video footage, the system can identify the exact scanner position or positioning area in the cross-dock and enable fast and efficient shipment tracking.

Enormous time savings and increased efficiency of warehouse processes

The precise recording of the position of goods using Location+ significantly increases efficiency in the warehouse. 

The combination of CargoVIS with indoor positioning enables us to save an enormous amount of time in many processes. For example, if a colleague is searching for a pallet at the dock, with the inbound scan, we can track the pallet and indicate where it is. Since we can easily locate the goods, we are confident about our actions. We can back up all the information we give to employees or customers with screenshots.
We are very satisfied with the solution. It’s a system that’s very easy to use, and really simple to learn. It’s very, very useful on a daily basis, especially in my role as a Platform Manager.”

Emmanuel Houelleu, Platform Manager at DGS Transports

Data platform replaces stand-alone solutions

Various additional Plus+ features allow different camera-based automation to be mapped and fully integrated via a single platform. This unique platform incorporates the Plus+ functions fully into the software solutions, eliminating the need for a multitude of stand-alone solutions. As a result, a wide range of data is collected along the goods flow in the warehouse, generating comprehensive added value for logistics processes.

In addition to Location+ for indoor positioning, the available Plus+ modules include volume control of goods (Scale+) and gate status detection (Gate+), which DGS Transports also uses. Thus, DGS Transports has access to an extensive ecosystem of different camera-based solutions. 

Volume control with Scale+ and the detection of gate status with Gate+ 

• With the software-controlled volume control in Scale+, it is possible to measure pallets without interrupting the loading process. The measurement is based on the evaluation of previously recorded video footage, allowing measurements to be taken directly in the software.
• Gate+ makes it possible to automatically detect gate and door statuses and close security gaps.

The combination of the collected data (e.g. video, location and measurement data) opens up extensive optimisation and savings potential for logistics processes. This increases the quality of logistics services while valuable time and cost savings can be realised at the same time.

Conclusion: DIVIS platform excels through versatility

The DIVIS solution has impacted the French company positively in several areas at once – its success as well, as Ludovic Charlec reports. The Chief Operations Officer is also enthusiastic about the cooperation: “The cooperation with DIVIS was a success. In the future, we will rely on DIVIS solutions because they are a perfect match for our tasks. They offer us a number of possibilities, such as monitoring and dimensioning, all in the same interface. It really is a guarantee of confidence and sustainability in the performance of these activities,” he summarises.

We chose DIVIS as our provider because our German partners often used DIVIS systems. We are an official member of the CargoLine general cargo network in the Paris region. Therefore, we were able to see this solution in use at our partners’ premises. That was a sign of trust and success for us.”

Ludovic Charlec, Chief Operations Officer at DGS Transports

DIVIS guarantees local support at all relevant customer touchpoints in France. In addition, DIVIS operates its own team for the French market, which supports customers from sales and project management to after-sales service in French.

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Mitsubishi Materials Corporation Sanpo Plant is a global manufacturer of copper and copper alloy products. The plant covers an area of 99,174 square metres and produces around 80,000 tonnes of copper products such as coils, sheets and rods annually. They have set out to solve the challenge of locating thousands of products in the manufacturing process and improve the efficiency of production processes.

Challenge: Streamlining Operations and Product Location

Mitsubishi Materials was looking for a way to streamline their operations so it didn’t have to waste time searching for the location of a specific product among thousands of products inside and outside the plant. At the same time, the company was looking for a method that would allow for proper production control.

In such a large plant, products based on metallic materials, which were always difficult to distinguish from the outside, were stored in different locations, and employees spent a lot of time trying to find a specific product. Improving operational efficiency became, therefore, a necessity.

Implementing Quuppa RTLS and Patt Plus Technologies

Mitsubishi Materials evaluated various technologies, including RFID and image recognition, to solve this problem. However, many issues remained that even these technologies could not solve in a plant that manufactures large metal products.

Ultimately, they opted for Quuppa RTLS technology, which provides highly accurate, real-time positioning of people and assets, and Kokusai Kogyo Co.‘s Patt Plus, designed to use the positioning data.

They installed the Quuppa Intelligent Locating System both inside and outside the plant and carefully tested whether the products could be located correctly and whether there were any new issues to solve.

At the same time, they repeatedly tested Kokusai Kogyo Co.’s Patt Plus to leverage the solution to improve operational efficiency by visualising location information and advanced management of production processes.

Increasing Production Efficiency through Precise Tracking

With the implementation of Quuppa and Patt Plus, Mitsubishi Materials can now instantly determine the exact location of their metal products, which was a challenge for the company. Using the exact location of their products, they can improve the accuracy of their production control, allowing them to identify and analyse problems in their production process and take appropriate action to improve.

Next Steps

Mitsubishi Materials intends to extend the use of Quuppa’s highly accurate, real-time location information to include worker safety management in the production process.

As a Quuppa Premium Partner in Japan, Kokusai Kogyo will continue to work with Mitsubishi Materials to solve various issues related to the further improvement of production processes.

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sepioo®: Reshaping Industrial IoT Processes

A powerful software and hardware platform, sepioo® is at the core of PDi Digital’s vision to transform fields within Industry 4.0, Smart Factory and IIoT. With its adaptability to any environment, sepioo® seamlessly links various IoT devices, such as displays, scales, sensors, and trackers, to essential business systems like SAP, Sklera, and ARIMS.

Offered as a Software-as-a-Service (SaaS) platform, sepioo® can be up and running in under 5 minutes, with the capability to scale to hundreds of thousands of displays within a single installation. Deploying the sepioo® platform can either be done by leveraging existing infrastructure thanks to the collaboration with leading access point (AP) providers or by opting for a standalone infrastructure offered by PDi Digital.

Digital Displays: Smooth Transition to E-Paper

PDi Digital displays, equipped with button-press control and NFC connectivity, offer adaptable two-way communication across a variety of industrial environments, including manufacturing, logistics, and healthcare.

These displays feature rapid response times and operate with energy efficiency, requiring power only during content updates while remaining maintenance-free for extended periods. They ensure excellent visibility from all angles, even when not connected to a power source. In manufacturing and logistics applications, adopting e-paper displays enhances visibility and control, streamlining processes like smart reordering and data collection, ultimately contributing to improved warehouse management.

Asset Tracking and Location-Based Information Services

With sepioo® displays compatible with the Quuppa RTLS system, organisations can track indoor assets with great accuracy and know their location with sub-meter accuracy. This allows critical information to be displayed directly on these assets using advanced e-paper technology. The platform enables users to set up automated workflows based on specific location-based data, such as triggering actions when objects move or when they enter or exit geofenced areas. This ensures that the right information is delivered to the right place at the right time, enhancing operational efficiency.

Future-proofing Design with Silicon Labs BG22 Wireless SoC

In their pursuit of designing robust display and sensor solutions, PDi Digital actively sought out a reliable wireless vendor to ensure the longevity of their designs and accommodate complex multi-protocol wireless connectivity use cases in various markets. Ultimately, PDi Digital chose the Silicon Labs EFR32 BG22 Wireless SoC due to its power budget with ultra-low transmit and receive power (3.4 mA for TX, and 2.5 mA for RX). With extremely low sleep currents, the BG22 SoC ensured industry-leading energy efficiency, extending the battery life beyond five years. Additionally, BG22 enabled PDi Digital to develop products that are compatible with the Quuppa real-time locating system (RTLS), utilizing the Angle of Arrival (AoA) technology.

This choice also came with a comprehensive software stack to enhance their solutions and the industry-leading security features with our Secure Vault, the most advanced level of security features.

The article was originally published as a Silicon Labs Case Study.

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Founded in 1951, Mitsuboshi Metal Industry Co., Ltd. is a manufacturer of rebar for various industries and enterprises. The company is based in Tsubame City, Niigata Prefecture. Mitsuboshi Metal produces high-quality rebar from steel scrap.

CHALLENGE

In April 2024, working hours regulations for truck drivers will be tightened by law in Japan, and Mitsuboshi Metal will be forced to respond to several challenges, including questions about the decline in transport volumes due to the worsening labour shortage. The average waiting time for truck drivers is about 18% of the daily working time, which is a problem, especially during peak hours—the working environment for drivers and shippers needs to be improved.

SOLUTION

Mitsuboshi Metal decided to tackle the logistical challenges with the solution provided by SATO Ltd., which includes QR codes and a real-time locating system powered by Quuppa. Mitsuboshi Metal’s industrial sites are harsh environments for solutions based on radio transmissions, yet Quuppa’s technology is renowned for effectively tackling the demands of such environments.

Using QR code labels, ID information, scanners and a real-time location system, each truck and driver can be identified and located when entering or leaving a berth (loading and unloading area), for example. The status of the loading dock area is visualised in real time and the user interface provides data on which truck is using which berth. For vehicles that remain in the loading area longer than expected, automatic alerts can be created and displayed, indicating the reason for the extended stay.

RESULTS

Mitsuboshi Metal has tackled their Logistics 2024 Problem and reduced the waiting time for truck drivers by 1,000 hours. Manual labour at vehicle reception operations has been reduced and measures can be taken to improve the efficiency of logistics operations and berth areas. By visualising the timetable of the trucks, Mitsuboshi Metal has shifted to managing reservations based on this information. In addition to the distribution of visiting vehicles, the factories can now prepare for shipment according to the reservations. The system can also be used to improve layout and operations.

The system has been awarded by the Japan Automatic Identification Systems Association (JAISA).

The SATO solution powered by Quuppa has delivered several benefits for Mitsuboshi Metal:

• The labour efficiency in the factories’ reception operations has been enhanced by saving the truck drivers time – by 1,000 hours a year.
• Less manual work in the reception operations.
• Better visibility into logistics processes.

NEXT STEPS

The SATO solution is an essential element on the road to Industry 4.0 at Mitsuboshi Metal. SATO and Mitsuboshi Metal will continue their cooperation and look for new use cases. The management is constantly looking for ways to maximise the value and quality of their products for customers. With a real-time locating system, Mitsuboshi Metal can improve logistics and transparency at its industrial sites.

Read more about the Sato solution powered by Quuppa here: www.sato.co.jp/products/realtime_locationsystem

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For K. Hansen Transport AS, ensuring high-quality logistics services is also a top priority. That is why the company has opted for the video management solution DIVIS CargoVIS, powered by the Quuppa Intelligent Locating System, for their shipment tracking.

Spoilt for choice: numerous locating methods available

There is an abundance of technologies at our disposal to determine our location. These technologies provide us with the data we need for seamless tracking, but it is important to recognise that not all of them are equally accurate or suitable for indoor applications. While GPS is sufficient for basic outdoor tracking, more accurate alternatives are required for indoor applications.

These alternatives include technologies such as Wi-Fi, ultra-wideband (UWB), RFID and Bluetooth®. For indoor tracking, the Bluetooth®-enabled Quuppa RTLS solution stands out as one of the most reliable systems available today. In logistics, the full potential of this technology comes to the forefront when it is integrated with a software-based video management system (VMS). Thank you for the synergy between camera-based package tracking and precise location data, seamless tracking of assets is achieved within seconds. This integrated approach provides a powerful solution tailored specifically for logistics operations. 

The Danish company K. Hansen Transport AS was looking for a combination of technologies that would add significant value to their operations. They needed a versatile video management system with tracking technology that would cover both the indoor and outdoor areas of their premises and fit seamlessly into their daily logistics processes.

Through a recommendation from a satisfied DIVIS customer, K. Hansen Transport discovered DIVIS CargoVIS video management software, which incorporates the Quuppa solution.

Seamless goods tracking indispensable

In extensive warehouse facilities with high shipment throughput, visual package tracking is indispensable to ensure quality control. In 2021, K. Hansen Transport AS implemented DIVIS CargoVIS video management software in six of its logistics warehouses. Another almost 8,000 square metres were equipped with CargoVIS, complemented by tagless Bluetooth® tracking with DIVIS Location+.

A notable advantage of this tracking solution is the elimination of hardware tags. The need for tags or transponders, i.e. small transmitters typically attached to scanners, has been eliminated. This tagging function is now seamlessly handled by an app developed by DIVIS.

When a pallet barcode is scanned using the Quuppa system directly from the barcode scanners (via app), the Transport Management System (TMS) or Warehouse Management System (WMS) records the scan data. Simultaneously, the Locators installed on the hall ceiling receive Bluetooth® signals from the scanners to indicate the exact location at the time of scanning. The app subsequently transmits the scanner’s position.

The location data is integrated into the CargoVIS database and correlated with the recorded video footage of the shipment. This results in a comprehensive data trail for each asset, enabling accurate tracking based on consignment or pallet numbers. Another advantage is that the fast search entry via scan points speeds up loading and unloading. With Location+, even the positions of concealed objects can be accurately determined.

The advantages of combining CargoVIS and Quuppa tracking with Location+ at a glance:

• Assigning goods location based on visual representation of the scanned goods
• Easy orientation within the camera images, facilitated by a clear visualisation of the scanning area
• Scanned objects identifiable in the camera images even when occluded
• Streamlining daily tasks with the Bluetooth® app
• High flexibility and subsequent integrability of scanners 
• Faster investigation through targeted access via scan times
• Efficient data interpretation thanks to the linking of scan, video, and location data
• Rapid amortisation of the purchasing costs.

One platform, many possibilities

In addition to the Location+ plus feature, the DIVIS platform offers logistics customers other plus modules that can be combined with the CargoVIS or ParcelVIS video software products used in parcel logistics. K. Hansen Transport AS uses License-Plate+, a database-supported system that enables automatic recognition of vehicle licence plates via video camera and simplifies access and yard management. The stored data can be used for entry and exit control and for controlling vehicle movements in the yard to ensure that only authorised vehicles enter the company premises.

Significant increase in efficiency

Thanks to the DIVIS and Quuppa solution, K. Hansen Transport has been able to significantly increase its operational efficiency. The absence of tags in this environment minimizes the occurrence of locating failures and errors, resulting in substantial savings by eliminating the expense of purchasing, repairing and maintaining small transmitters. These improvements lead to significant gains in efficiency, cost reduction and the streamlining of unnecessary tasks for our staff. The strengths of the solution are also evident in logistical environments where many scanners need to be located accurately. Installing the DIVIS app on new devices effortlessly integrates the scanners into the tracking system. Thanks to these comprehensive process optimizations, the solution quickly pays for itself.

Conclusion: Success all along the line

Location+ with tagless Bluetooth® tracking has improved various aspects of K. Hansen Transport, from loading processes to claims management. In addition, customers now experience a higher quality of service. Director Jakob Wiborg Hansen expresses his satisfaction with the partnership with DIVIS, particularly in the areas of sales and service.
In his own words:

The cooperation with DIVIS has been highly effective, and we are very content with the system.”

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If you’re unfamiliar with the process, cross-docking is a practice in logistics management that involves unloading incoming deliveries and loading the materials for outbound delivery. At these kinds of facilities, packages go in and out the door within a matter of hours. There are typically no storage racks nor any long-term storage infrastructure. The underlying idea is to efficiently sort and dispatch packages to provide faster delivery of goods from supplier to end customer. 

But the immensely spacious open floor plan, combined with an increasing amount of goods handled daily, can lead to more than a few degrees of chaos.

So how can goods most efficiently be transported from inbound to outbound delivery systems? More and more facilities are looking at real-time location systems (RTLS) to track operational flows inside the facility. A combination of RTLS and video monitoring can also provide a more complete picture of the facility and its fast-paced operations, reducing liabilities and process errors. 

The Missing Link

At these sorts of temporary holding facilities, you don’t have time to misplace a package: it has to be accounted for and its location known at all times. The sheer volume of goods, the speed of sorting, and the fact that all items are in motion within the facility cause major operational challenges. That requires a high level of workforce coordination to address and overcome. 

Because cross-docking warehouses typically do not contain designated storage areas for specific goods, packages are often transported directly to the outbound docks, where a truck or van is waiting for loading and can quickly take off for delivery. The goods are moved from inbound to outbound docks via transportation units, which can be everything from roller cages to pallets.

The process generally works like this: packages are unloaded off delivery trucks, brought to a sorting machine, sent down a chute, and divided into transportation units. Some cross-docking facilities utilize a distribution conveyor with chutes assigned to end destinations, but others may use forklifts to transport pallets of goods directly from inbound to outbound.

Without the ability to efficiently coordinate the workforce and available equipment (forklifts, pallet jacks, roller cages, etc.), the loading/unloading process can be delayed, which would then cause issues down the line. Cross-docking facilities move everything in bulk at lightning speed, and a single mistake or bottleneck is enough to ground operations to a halt. One stalled outbound delivery, and packages started to pile up. 

So in essence, a dedicated cross-docking facility must be designed to move inbound pallets from the receiving dock to outbound trucks without hiccups in between, monitoring every step of the sorting process. But that can’t be achieved without some sort of internal tracking mechanism. You need maximum optimization. 

Selecting and implementing RTLS 

There are numerous wireless RTLS systems available based on a variety of technologies, such as Bluetooth, Wi-Fi, and Radio Frequency Identification (RFID). Any of these systems enable operators to monitor the movement of goods to varying degrees from the moment they arrive to when they are loaded onto outbound delivery vehicles. But how can the benefits of RTLS be realized in a facility where speed is crucial and adding time-consuming extra steps to the process is simply not feasible?

The venue, use cases and type of tracked items are leading factors that should shape your system selection. To choose an RTLS system right for you, assess your facility’s existing infrastructure, including the possibility to deploy new infrastructure power sources availability, and data network capabilities. Ensure that the specific site constraints can support the chosen RTLS technology. Typically the facility manager, with the help of technology vendors, should also conduct a thorough site survey to identify the characteristics that will impact realizing the target use cases; e.g. optimal locations for RTLS hardware components, optimal specs for the tags, type of mobile handset, , and what exactly should be supported for a successful system deployment and configuration. These steps help ensure proper coverage and accuracy, as well as optimize the overall solution price. 

Remember all systems have their pros and cons. You thereby need to identify specific goals and objectives when selecting an RTLS system for a cross-docking facility. Determine which areas need to be covered and what use cases you need to solve, such as monitoring inventory, tracking assets in the shopfloor, or optimizing yard management. Your answers will guide you through the selection and implementation processes. For instance, in congested and fast-paced cross-docking facilities, you’ll want a system capable of tracking a high volume of assets quickly and with high reliability. 

It’s worth noting RFID systems have limited range and accuracy outdoors due to interference from metal, water, or dense foliage. So this system wouldn’t be suitable for monitoring goods when they’re being offloaded from inbound trucks. Instead, consider opting for a hybrid system that can work from outdoors to indoors for seamless tracking. 

Alternatively, tagless RTLS is a less resource-intensive option where goods can be tracked via a barcode scanner or QR code rather than a physical tag. A handset scans the code of the goods to record the location at the time of the reading. This allows goods to be traced throughout the facility with less physical hardware, which can quickly add up in price while still providing valuable location information. 

Ultimately, when it comes to logistics, the more visibility you have, the better. And the less time you have to spend gathering that information and searching for resources, the better. Gone are the days of employees frantically running blind across ten thousand square foot facilities. We’re now looking for ways to develop a well-oiled logistics machine, and that can’t be done without real-time location systems.

This article was originally published on Forbes.com.

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Understanding Quuppa Lite and
its Unique Features

Quuppa Lite is a versatile solution that offers an affordable and flexible option for inventory management and creating environments with mixed accuracy levels. While Quuppa Pro provides precise location tracking, Quuppa Lite focuses on providing approximate location information, making it suitable for scenarios where pinpoint accuracy is not necessary across the entire facility.
Quuppa Lite offers a more generalised view of asset location, providing information on which area an asset is located (presence detection or area presence). This flexibility ensures that businesses can focus their resources on areas that require precise tracking while still having a general understanding of asset location in other parts of the facility.

Lower Deployment and Operating Costs

Implementing Quuppa Lite comes with a range of benefits that can significantly improve inventory management processes while reducing operating costs. One of the primary advantages of Quuppa Lite is its affordability due to reduced deployment and operational costs. The simplified infrastructure requirements make it a cost-effective choice for businesses looking to optimise their tracking systems without incurring significant expenses.

Furthermore, Quuppa Lite offers cost savings in terms of subscription fees. Its affordable nature and simplified infrastructure requirements reduce subscription costs compared to more precise location tracking solutions. This affordability makes Quuppa Lite an attractive option for businesses looking to optimise their tracking systems while controlling costs.

Easy Deployment of Quuppa Lite

Quuppa Lite is designed to be easy to deploy, minimising the time and effort required to set up the system. The simplified installation process allows businesses to quickly integrate the Quuppa system into their existing infrastructure.

Start Light and Scale to High-Accuracy Tracking

While Quuppa Lite provides approximate location information, businesses always have the option to upgrade to Quuppa Pro for high-accuracy tracking using the same Quuppa system and hardware. The upgrade option eliminates the need for the complexity of managing multiple tracking systems and simplifies overall infrastructure requirements. As a result, businesses can reduce costs associated with maintaining and managing separate tracking solutions.

Real-Life Use Cases

Quuppa Lite has proven effective in various real-life use cases, enhancing efficiency and productivity in inventory management, especially in storage areas. In a busy warehouse with numerous storage sections, keeping track of inventory can be challenging. Quuppa Lite offers a solution by providing approximate location information on assets within different warehouse sections.

Similarly, in large logistic centres, tracking packages and goods in real time is crucial for optimising operations. Quuppa Lite can provide valuable insights by offering site-level accuracy, allowing businesses to monitor the movement of packages and goods throughout the supply chain. This enables better planning, improved routing, and faster response times, ultimately enhancing the overall efficiency of the logistics centre.

Presence detection in charging areas is another use case where Quuppa Lite shines. Charging areas for assets such as electric vehicles or portable devices require efficient management to ensure a smooth charging process. Quuppa Lite can detect the presence of assets in charging areas, providing real-time updates on asset availability and enabling businesses to optimise charging resources. This ensures that charging areas are utilised effectively, reducing waiting times and maximising asset utilisation.

Gateway Functionality and Back-channel Commanding

Quuppa Lite offers gateway functionality, allowing seamless integration with sensors and other devices. As a data gateway, Quuppa Lite can collect data from different Bluetooth® sensors in the environment and expose them through an open API. This eliminates the need for multiple infrastructures and allows businesses to leverage Quuppa Lite as a gateway for all. For example, in manufacturing, businesses can pair data from weight sensors with location data to monitor (e.g. bolts, oil) inventory levels and trigger alerts when replenishment is needed.

Quuppa Lite also supports back-channel commanding for tags, enabling businesses to send commands to tags and receive responses. This capability opens possibilities for automation and real-time asset management. For instance, businesses can use back-channel commanding for pick-to-light use cases, improving accuracy and reducing errors in picking operations.

Summa summarum

Quuppa Lite not only offers a cost-effective solution but also turns the Quuppa system into a versatile solution that can address the different needs of businesses, optimising their inventory management processes and building mixed environments without compromising reliability and real-timeliness. With its unique features, such as lower operating costs, easy deployment, upgradability to Quuppa Pro, scalability, and gateway functionality, Quuppa Lite empowers businesses to make informed decisions based on location data.

Real-life use cases demonstrate the effectiveness of Quuppa Lite in enhancing efficiency and productivity in various industries, such as inventory management in storage areas, logistic centre tracking, and presence detection in charging areas. The power of Quuppa technology, combined with integration capabilities and cost savings, makes Quuppa Lite an attractive choice for businesses seeking cost-effective and reliable inventory management solutions.

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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.

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Founded in 1979, KISSEL Spedition GmbH constructed a new logistics site in Mainaschaff, Germany, in 2021. The family-owned company now has modern logistics facilities, including a new 9,000 m² transhipment hall with 82 hall doors as well as a new 5,000 m² logistics warehouse with 5,500 pallet slots and 42 vehicles or forklifts. About 350 professionals deliver logistics services at the site and process 7,000 packages daily. 

CHALLENGE

KISSEL Spedition wanted to improve the operational performance, process automation and safety in their services and operations. Efficient logistics requires functional facilities and modern information technology solutions. KISSEL Spedition offers a wide range of logistics services and has invested heavily in modernising their logistics infrastructure and processes. 

KISSEL Spedition wanted to improve the operational performance, process automation and safety in their services and operations. Efficient logistics requires functional facilities and modern information technology solutions. KISSEL Spedition offers a wide range of logistics services and has invested heavily in modernising their logistics infrastructure and processes. 

The company works closely with PKE Deutschland GmbH, their information technology partner. In today’s digitalised logistics business, assets can and need to be tracked in all areas within the buildings. The logistics company wanted to make relevant information available more quickly and easily to all professionals and drivers working in Mainaschaff, whenever and wherever it is needed. The goal was to utilise indoor location technologies and automation as smart as possible with the help of PKE’s professionals.  

SOLUTION

With the help of PKE, KISSEL Spedition was one of the first pioneers in logistics to implement a FullHD IP-based camera system in its operations in 2009. Today, KISSEL Spedition uses advanced software and hardware, including 207 IP cameras both inside and outside the buildings. PKE supplied Mainaschaff the Video, Locating and Software (VLS) system, including the indoor locating system powered by Quuppa. The robust and reliable system tracks scanners, forklifts and pallets 24/7.

The Bluetooth function is installed into the scanners by default and, in combination with the VLS system, provides real-time location information directly into the application. When pallets arrive in the weighing area, the VLS system automatically sends the information into the weighing application. The stored location data can be combined with the data received from the video cameras. The indoor cameras deliver images from all scanners into the transhipment application SLS providing employees direct access to the data.

The inventory of all pallets can be done fully automated every day. All vehicles and forklifts can be identified when they arrive, for example, at a hall gate enabling automated access control. The warehouse office area and 50 hall doors have been equipped with access control and automatic alerts in case of breaches.

RESULTS

The PKE solutions powered by the Quuppa indoor tracking system fulfil many business requirements at KISSEL Spedition’s challenging logistics indoor environments.

The accurate, continuous and dynamic tracking solutions offer several benefits to KISSEL Spedition:

• Gives a new dimension to a fast-paced logistics environment by reporting the positions of scanners, pallets and vehicles in real time.
• Improves the operational logistics performance and the automation level at the site.  
• Allows logistics professionals to get the needed information faster. 
• Enhances cooperation and saves time.
• Automates processes and improves site security. 

NEXT STEPS

As a next development step, KISSEL Spedition plans to implement the AVASYS® security management system introduced by PKE. The system centrally steers the security technologies and connects them with other systems like the weighing application and the building automation and services systems.

For more information, visit v-l-s.com

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VEO manufactures low and medium-voltage switchgears for various purposes, as well as control systems, automation and drive system cabinets. The search for tools at the company’s headquarters in Vaasa, Finland, had become a daily challenge for the technicians. They hoped to find a solution that would help them find the tools they needed quickly and easily.

Solution

“Our partnership with Trackinno started in 2021 when we realised that we really needed help in the indoor positioning of our tools and devices. Every day our employees had to spend too much time searching for tools and we did not have up-to-date information on what tools we already had. Trackinno solved this problem for us with a well-functioning indoor positioning system,” says Reijo Paalanen, Production Development Manager at VEO headquarters in Vaasa.

Indoor positioning was introduced at the Vaasa factory with a pilot test, after which the positioning system was extended to the entire factory. With the help of Locators on the ceiling and tags attached to the tools, technicians can now track the location of the tools in real time.

Results

“Trackinno’s mobile app is clear and easy to use. It has helped us direct our resources to the actual tasks instead of searching for items. I am glad we no longer have to spend so much time running back and forth in the hall,” says Peltoniemi.

Next Steps

Thanks to indoor positioning, all calibration certificates are now gathered in one specific location where employees can easily find them. The visible benefits achieved through intelligent indoor positioning have also been noted by Mikko Peltoniemi, who has worked at VEO for ten years.

According to the employees, indoor positioning has met their expectations and there is no turning back. The system is constantly being developed together with Trackinno’s experts, taking individual needs into account.

“Cooperation with Trackinno is really great; they are always there for us when we need help. It’s great that we can continue to develop the software to meet our needs even better. Trackinno’s easy-to-use indoor positioning system has met all our needs, so I can truly recommend it to others,” says Paalanen.

For more information, visit trackinno.com.

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