Showing posts with label Manufacturing. Show all posts
Showing posts with label Manufacturing. Show all posts

Friday, December 12, 2014

Contactless Technologies Conference – Lille, France

Ubisense Real-Time Location and Manufacturing industry experts Christian Raux and Hubert Peyre presented at the Contactless Technologies Conference in Lille this week. The event, held on December 9, was entirely dedicated to indoor location technologies.

Ubisense is a global leader in Enterprise Location Intelligence solutions for Manufacturing, Communications and Utilities companies. We enable some of the world’s largest businesses to improve operational effectiveness, significantly increasing their profitability. Christian and Hubert were among the few speakers at the event who were demonstrating the powerful benefits of location intelligence solutions in industrial applications.

Ubisense engineers have over 30 combined years of in-service operation with our flagship product Smart Factory, which is used by top automotive and aerospace companies around the world. Smart Factory is a production-certified system, designed specifically to help manufacturers sustain continuous flow, optimize efficiency and reduce errors in manual assembly processes.


The conference in Lille was a fantastic opportunity for Hubert and Christian to talk to customers, prospects, and other industry personnel, and to demonstrate the limitless possibilities for operational improvement that location intelligence solutions can deliver.

For more information on Ubisense, visit our website at www.ubisense.net.Or to find out about the event, click here:









Friday, October 24, 2014

Don’t Get Lost in the Hype

By Adrian Jennings, CTO Americas

Yesterday, I hosted a webinar, Visibility in Manufacturing: The Path to Industry 4.0. To a handful of manufacturers, the coming age of cyber-physical systems is the inevitable next step. For most, however, these concepts are decades away from mass adoption. I advise you not to worry.


Don’t get lost in the hype.


Instead, focus on mastering Industry 3.0 concepts, more specifically - automation, to gain greater visibility and control over your manufacturing operations in the nearer term. Tackling visibility from process to product to department and eventually throughout your entire organization, will feed into and support your ultimate path to Industry 4.0.

Listen, I meet with manufacturers often and I am consistently asked how they compare to others in the industry. So during the webinar, we asked attendees a few questions about the state of their manufacturing operations. Below is the Q&A we conducted.


How close are you to adopting Industry 4.0?
Doing it now 36%
Plan to start in 2015 21%
It's in our five year plan 21%
We haven't even thought about it 21%


Do you spend at least an hour a day searching for assets or products?
Yes 79%
No 21%
How many variations of a product do you build on a single line?
One 0%
Tens 38%
Hundreds 31%
Thousands 31%
What is the main cause of manual errors in your plant?
People 60%
Process 40%

What percentage of wireless tools do you have in your plant?
0-10% 46%
11-20% 31%
21-50% 23%
51% and up 0%

Interestingly enough, the results collected during this webinar are in line with the survey we conducted over the summer that reflects answers from more than 250 manufacturers. So what does this tell us? Many things really, but fundamentally – manufacturers need more visibility so they can improve productivity, efficiency, and their bottom line.

How can manufacturers gain more visibility? During the webinar, I outlined a few steps to consider:

Be Selfish – Start small and local. Pick a pain point and tackle it. Prove to your organization and yourself that the technology you choose works.

Be Forward Thinking – Understand your next step and ultimate goal and invest in the right infrastructure from the outset.

Be Cooperative – Share your success and work with other people and departments. There are significant benefits when the entire organization invests in technology that contributes to greater visibility and control.

Be Supportive – Guide other plants through the process to help the organization prepare for the final step – Industry 4.0.

If you’d like to learn more, you can access the webinar on-demand at http://bit.ly/ZJFbwh. Of course, if you have any questions please contact me at Adrian.Jennings@ubisense.net.

Thursday, October 16, 2014

How Do Manufacturers Gauge Performance or Use Real-Time Information?

The 2014 Smart Manufacturing Technologies Survey was designed to collect feedback on how manufacturers use real-time intelligence and to gauge performance indicators such as unscheduled downtime, productivity, and quality issues. The findings from this survey provided Ubisense with a snapshot of the state of the manufacturing industry and clarity into current market needs. This insight helps Ubisense optimize its Smart Factory solution which enables manufacturers to turn data into knowledge and dramatically increase the visibility of their products, movements, and locations. 

Download this Free White Paper to Find Out





Thursday, October 02, 2014

The Promised Land

Written by: Adrian Jennings, CTO of real-time location intelligence solutions

When I was a budding rocket scientist playing with missiles in the wilder parts of England, it always seemed to me that my colleagues across the pond in the US had it so much better. I imagined they were better trained, better resourced and altogether lived in some kind of Promised Land. When I eventually moved to the US I’m not sure whether I was gratified or disappointed to find that they had all the same constraints and issues we faced in the UK. In fact, we had pioneered some techniques that the US was keen to learn.

I imagine it must sometimes feel the same working in a manufacturing plant and reading in the press all about cyber-connected systems, Industry 4.0 and the like. It must often feel like everyone else has better technology and better processes than you, and surely that means they are much farther ahead.

Well, just as I discovered when moving to the US: they don’t have anything better than you, and they aren’t any further ahead. Ubisense’s recent survey of smart technologies in manufacturing revealed exactly that. Whereas a few pioneers have adopted advanced manufacturing technologies, most plants still rely on mostly manual processes and have a distinct lack of operational visibility.

The results of the survey are available in a white paper, which also discusses a path to better visibility and better processes – one that doesn’t require huge technological leaps into some imagined Promised Land. Have a look at the white paper: http://bit.ly/1vpRUPm. You might be comforted to know that many others face the same problems you do. And who knows – maybe you’re the one who’s ahead?


Tuesday, May 27, 2014

Leveraging Location Data to Uncover the Hidden Factory

Written By: Darcie Cousins, Technical Sales Consultant, UK

By consuming location data in real-time and transforming it into visible, actionable information, Ubisense solutions reveal the ‘hidden factory’ and empower managers and executives to improve production processes, improve product quality, and automate key business processes to make their operations leaner and more efficient. 

What does that actually mean? Well, here is one analogy that might help, and it’s all about location.

Twenty years ago, if you wanted to get from Point A to Point B, you probably pulled out a paper map of the region you were traveling in. You may have had to take some time to locate your start and end points if you weren’t already familiar with where things were. Then you would assess your various route options and plan the best possible route according to your priorities – fastest, shortest, most scenic, etc.

It was time consuming and somewhat risky. Your map probably didn't show road construction and if it was out of date your planned route may not have been the most efficient – newer, larger roads might have been built that would have been a better option had you known about them. If it was a long journey, the map may have had some service stations marked but for the most part finding places to stop or eat along the way was all part of the "mystery" and "adventure" of the fabled road trip.

Once you set off, you were never sure what was just around the corner. How many times did you sit for hours in bumper to bumper traffic because of an accident or road construction? How many greasy diners did you eat at, not knowing your favorite healthy restaurant franchise was just one mile away? Did you ever really know what ETA to give your anxious relatives waiting for you? Have you ever spent a nervous hour driving through the desert hoping to find a service station with the fuel gauge dropping lower and lower? I have.

Kids today have no idea what this was like – it is the 21st century equivalent of the "walked ten miles to school with no shoes" stories our grandparents told us. This is because today we have smart phones, and these phones are running location aware applications.

Have you ever thought about how many of the apps we use daily are using location data to make our lives better and easier? My phone lists dozens, including apps for fitness, bird watching, shopping, weather, public transportation, parking, and travel. Now when I want to take a road trip I load a crowd sourced navigation app. It offers me multiple route options to choose from and displays trip distance, time, and current traffic conditions along the way. It lets me send my ETA to a friend, and even provides a link for them to monitor my trip progress in real time. Other users enter information about traffic conditions, accidents, or hazards in the road in real time, and the app will offer me a new route to help avoid them. 

All of this functionality makes travel much more efficient and pleasant than it used to be. It eliminates a lot of wasted time, effort, and energy by giving me all the information I need to make the right decisions according to my goals and preferences – and all in real time.

Ubisense Real Time Location Intelligence (RTLI) solutions are designed to bring the time and money saving features of these applications we all take for granted in our personal lives and apply them to business environments. Using the Smart Factory product set, manufacturers are able to answer important questions about the current state of production using information provided in real time. 

The system consumes location data that can come from various sources – Ubisense sensors and tags, handheld barcode readers, passive RFID tags and readers, PLCs, and so on – and transforms it into business intelligence. Businesses who have invested in this technology are now able to understand the secrets that were previously hidden in the factory:
  • Where is Product123 right now?  
  • How far through the production process is Product123? (Is it running on time?)
  • Are there any known quality issues on Product123? (Is it in rework?)
  • When is Product123 likely to be finished? (Is it at risk of exceeding the target production time?)
  • What tools have been used to assemble Product123? (Does this match the bill of materials for that product?)
  • What is the average time that products are spending in process step 4? (Is this in line with our performance goals?)
  • Does process step 4 take more time for some types of products than others? (Let’s look into why.)

Smart Factory includes a powerful rules and events engine that is able to monitor for specific situations and proactively alert production leaders to events they are interested in:
  • The Ageing WIP KPI is in danger of being exceeded for product123. (It needs to be prioritized.)
  • Workspace 4 can only accommodate three vehicles, but four have been parked there. (This carries an increased risk of paint damage.)
  • A vehicle with an unresolved electrical fault just entered the Pass to Sales area. (It must be repaired it before it leaves the site.)
  • A part that is vulnerable to corrosion has been in a workspace longer than it should be. (It must be protected to prevent scrap.)
  • Part123 just deviated from its defined production workflow. (It needs to get back on track.)

Smart Factory can add value to production processes on its own, or act as an ‘enabling’ technology augmenting existing Enterprise Resource Planning (ERP), Manufacturing Execution Systems (MES), or Manufacturing Operations Management (MOM) systems. It provides the location intelligence that takes manufacturers out of the age of paper maps and brings them into the age of smart applications. Just as technology as made travel safer and more efficient, Ubisense RTLI solutions make navigating your business more efficient and cost-effective. 






Wednesday, May 14, 2014

21 Ways to Chase Waste with Smart Factory


Eliminating waste is an important part of improving your production system. The old way of chasing waste was to wait until it popped up and then chase it down. This reactive approach does not achieve meaningful improvements, and it drains your organization’s energy and resources.

There is a new way to chase waste: use an indoor location tracking solution and let it tell you what you need to know before it becomes a problem. Indoor location tracking can:
  • Notify you immediately when something unexpected occurs, such as a missed step or an incorrect process sequence. Notifications can be done by email, SMS, or visual alert.
  • Help you find inventory that is stuck, abandoned, or misplaced so that all of your equipment is properly utilized.
  • Identify process bottlenecks with real data to help justify change or future investments.
With real-time maps, event alerts, and location information, you can find and eliminate waste efficiently and proactively!  
 
Visualize Your Factory 

Ubisense Smart Factory allows you to easily search for, identify, and find an asset in real time. We know you have goals to meet and products to produce, so we have made our solution simple and intuitive; technology should enable you, not hinder you. Let us show you how it can make your job easier, your processes more efficient, and help you achieve your goal of eliminating waste.

Tuesday, April 15, 2014

Ubisense in Action: Hannover Messe


Picture: Dr. Andreas Schurzinger demonstrating Smart Factory at

Ubisense Smart Factory installed at Daimler

Since the beginning of July 2013, Ubisense Smart Factory is in production on the Mercedes S-class assembly line in Sindelfingen, Germany. In a pilot phase, the system was tested and integrated with the DC tools in two line segments. The remaining stations were then equipped and all the DC tools were integrated in the subsequent step, which went live in July.

Smart Factory is used in the Sindelfingen plant to identify vehicles and assets on the final assembly line and to control tools based on their position. Linked to the vehicle ID, the real-time tracking data is also transferred to other systems in the production facility, so machine operators always know which particular vehicle is arriving at a station—even on those line segments where conventional vehicle sensing systems cannot be used. Cumbersome, manual scanning processes are thus eliminated, vehicles and tools are matched automatically and the correct tool programs are loaded at the respective work stations. As a result, unproductive assembly time is reduced significantly and errors that can occur with manual processes are avoided.

Smart Factory is integrated seamlessly with the car manufacturer’s PLUS manufacturing execution system and allows for a direct control of the DC tools via the Atlas Copco Open Protocol. In the full roll-out, devices and tools provided by other vendors are also controlled via the real-time location data. The system was implemented by Ubisense together with Atlas Copco, who have a strategic partnership since 2009.

Tuesday, February 25, 2014

"Big Challenges Off the Road" by Automotive Manufacturing Solutions

The volumes may be lower and the unit size larger, but the logistical and manpower issues involved in off-highway manufacturing are similar to the automotive industry
CaterpillarThe manufacture of huge off-road vehicles follows many of the same processes found in automotive production. Most of these models are made using flow line processes with line-side kitting and sequenced logistics; the main difference comes in the sheer size and weight of the components and subassemblies.

The Caterpillar Peterlee facility in Durham, UK, is the worldwide manufacturing location for Caterpillar Articulated Trucks and currently produces a six-model range, four with different engine variants that tip the load and two which eject it. Phil Handley, facilities managing director, explains: “We make vehicles with a capacity starting at 25 tonnes right through to a 43-tonne machine. We have machines that we sell into regulated countries from an emissions perspective – tier 4 compliant machines – and we have machines that we can sell to the rest of the world where the emissions regulations are not quite as tight.”

Product variation is quite limited. Unlike their automotive counterparts, off-road vehicle manufacturers generally do not face the constant churn of new models on an annual basis which necessitates re-tooling and significant line changes. “Our cycles are very different from automotive models and lately they tend to be emissions driven,” states Handley. “We are just going through the launch of the tier 4 compliant product along with most of our competitors,” he says, adding that elements of a base model tend to be updated before a new generation is launched.

In addition to the narrower model range, paintshop is less taxing; the majority of construction equipment is yellow, although specific colour schemes for off-highway vehicles such as military camouflage are sometimes requested.
 

Scope as well as scale
Handley refers to the manufacturing philosophy at Peterlee as “flat plate to gate”, with only the drivetrain not manufactured on site. All the drivetrains feature Caterpillar components (gearboxes, axles and engines) that are brought into the plant in sequenced line-side deliveries.

“We receive flat sheet steel and then go through the standard processes where we cut, bend, weld, paint,” he explains. “We then have a single piece flow line where we assemble various models. It is not actually a physically moving line such as you would find in an automotive assembly plant, but we use product movers to index move the machine along the line as it grows.”
 

There is only a small amount of automation. “We use laser cutting technology and we use robots for welding,” says Handley. “We have an automotive paint plant, but that is not automated. There is more automation in the fabrication process as there are more repeatable processes that we can modular-build.”

When it comes to capacity, line speed and throughput, Handley is somewhat cagey. “We have got capacity in place that meets industry demand and we are continually investing in that capacity,” he states. “We are flexible with our working patterns; we can move people in and out of the process to match the seasonality or cyclical demand, so we can manage peaks and troughs with our process.”

Tackling the size issue

From an automotive perspective, the major difficulty with off-highway vehicles is their sheer size. “The scalability is certainly a challenge,” Handley says. “But you have to bear in mind that, compared to some of the large mining trucks that are manufactured elsewhere within the group, our product is not particularly large; you would fit our completed truck inside the body of one of those [trucks].”

Nonetheless, Handley admits that the scale of moving the parts is certainly a challenge. “But we make our own trolleys and stillages and we have huge cranes to move the components around,” he states. “The actual dump body sits on a special stand that can be raised by a fork-lift and moved to a required position.”

Along with the size and scale of the components, there are ergonomic issues to be addressed. “You need the people who are involved in the manufacturing process to be safe and to be able to move and manipulate heavy components,” explains Handley. “So that can become a challenge and we have had to develop some bespoke equipment that we use to fit various components to the machine.”

A further complication caused by the size of the vehicles, components and assemblies is the space needed for line-side logistics. When working on a flow line, modules need to be available at the right point and at the right time. According to Handley, some of the order-specific, sequencing activities where various options are matched with the product as it moves along the line mean that a large area is required. “We don’t have a lot of opportunity for things to go wrong as we are moving through the manufacturing process, as realigning products is difficult.”


The active tags used in Ubisense’s Smart Factory System transmit data several times per second
Manpower and ongoing needs
Another key challenge faced by Caterpillar and other heavy vehicle manufacturers is staffing. “Along with the process, it is the skills that are our biggest problem,” confirms Handley. This means attracting, developing and retaining the skills that are needed across the full range of positions: welders, fabricators, painters, electricians, manufacturing engineers and design engineers.

“It is quite a challenge attracting young, talented people into the industry,” states Handley. He believes the problem is particularly acute in the off-highway sector: “Maybe automotive companies don’t find it so difficult, but at this end of the market we do." He explains that heavy manufacturing is "not always viewed as an attractive career” because it is seen as a “dirty, dark and dank type environment” – but that this is far from the truth. Peterlee, for one, is a high-tech facility with a clean environment despite the heavy fabrication.
Placing progress in real time
At the AGCO factory at Marktoberdorf in Germany, a recent installation of a Manufacturing Execution System (MES) was being hampered by incorrect data entry during the assembly process. The company opted to automate this activity using the Ubisense Smart Factory System. Over the 4,000m2 area, AGCO fitted 76 sensors and 200 real-time location system (RTLS) tags. By precisely tracking the tags on each gear assembly as well as on each subassembly, the company achieved real-time progress monitoring.

“Typically, manufacturers are relying on an operator manually typing in information on a workstation about the job in process,” says Terry Phebey, Ubisense vice-president of marketing. For instance, a gearbox assembly would come into the bay and at a quality control point a worker would have to type information into a terminal or scan a barcode. By instrumenting the area, AGCO was able to eliminate the human data input. The entry of the assembly into the space automatically sends intelligent data to the MES, entirely machine-to-machine.


“All that is required is that at the start of the process the tag is fitted to the part or assembly and an association is made between that part and the serial or bin number,” explains Phebey. “The Smart Factory System uses high-precision UWB real-time location technology combined with GPS for outdoor applications,” he adds. “Users only need three components: active (battery-powered) transponders or tags, designed for different applications; sensors; and software.”


The tags have a unique ID and can, for example, be associated with production data and transmit location radio signals to sensors, which detect the signals and calculate the positions of the tags several times per second. The Ubisense software stores, processes and displays the location data in real time for the user as well as generating events for IT or shop-floor systems.
Customers usually start with a small zone and just a few sensors as proof of concept, then, when they are happy with the ROI and quality metrics, the system is rolled out across the entire assembly process.

Thursday, January 02, 2014

Selecting a Location Intelligent System: Accuracy & Tag Range

When evaluating the suitability of various location intelligent solutions, it is useful to have some technical understanding. In the following blog post we will discuss how location accuracy and tag range play an important part in choosing a location intelligent system. 

LOCATION ACCURACY AND LOCATION CONSISTENCY
Location based applications are most often compared in terms of the accuracy provided by the sensor system. Location accuracy is certainly a critical parameter for quantifying system performance, but when quoted out of context it can prove misleading. A location sensor system is only fully defined when location accuracy is quoted in conjunction with a consistency metric.

Consistency in this context means a measure of how often the location system delivers the stated accuracy. The game of darts provides a simple example: even the most amateur player can score a bulls-eye if enough darts are thrown, but the measure of a good player is: how often can he or she hit the bulls-eye?





Figure 4-1 (above) shows an example of the output of a typical location system (or, the places where the dart hit the board in the above analogy).

This plot is generated by counting the number of measurements that lie within the error circles shown in Figure 4-1. In this example, 20% of the measurements lie within the 3’ error circle, 70% are within the 15’ circle (including those in the 3’ circle) and 97% are inside the 30’ circle. Figure 4-2 shows that data plotted in blue. The orange line shows an example location system with a much tighter constellation of measurements around the true location, with 95% of measurements inside the 3’ error circle.

The blue and orange lines in Figure 4-2 represent a true comparison between location technologies. By simply comparing location accuracy, misleading results can be interpreted if the accuracy figures are quoted at different consistency levels. In the darts analogy, the orange line represents a good player, and the blue line a poor one.


Figure 4-3 shows how consistency levels become important in location enabled applications. In this figure seven zones are shown, with the item being tracked located in the center zone. In the case of a 3’ error measurement the item is correctly associated with the center zone. When the error is 15’ the item could be in one of three zones, and with 30’ error in one of five.


Reading from Figure 4-2 the different location systems can now be fully compared as shown in Table 4-1.


The importance of Table 4-1 is that it compares systems based on not just how well they perform, but how often they perform to that level. It’s clear that both systems can claim to identify the location of a tag to within a single zone, but that the high accuracy system does so with significantly more consistency than the low accuracy system. In a real production environment, location system performance must exceed 99.9% for many mission critical applications.

OVERVIEW OF LOCATION TECHNIQUES
All location intelligence technologies share the common theme of some kind of tag attached to the object being tracked, and an infrastructure of sensors that determine the ID and location of the tag. Such tags may emit optical, ultrasonic or radio frequency energy, but radio frequency (RF) tags are the only ones suited to industrial environments (since optical and ultrasonic signals are too easily jammed or blocked in typical factories).

In all cases the sensing infrastructure attempts to measure either the range or bearing (or both) to a tag from one or more sensors and from that information the tag’s location is calculated. The technologies are predominantly differentiated buy how well they are able to measure range and/or bearing and, as a result, how accurately they are able to determine tag location.

MEASURING SIGNAL STRENGTH
Many location systems make use of the fact that the signal strength from a tag becomes weaker as the tag moves farther from a sensor. These systems measure the signal strength measured by multiple sensors, use that information to estimate the range of the tag from each sensor and then calculate the tag location. Figure 4-4 shows how this works.

In Figure 4-4 it is clear that three sensors are required in order to locate a tag in two dimensions. (By extension, four sensors are required for a 3D location determination.)

Tag location errors are cause by many sources, the dominant of which being variations in signal strength caused by effects other than range. If some other effect acts to reduce the signal strength then the sensor interprets this weak signal as longer range than reality. Figure 4-5 shows how range errors from each sensor contribute to overall tag location error.
Range errors are the limiting factor of signal strength systems since many factors affect signal strength beyond just the spacing of the tag from the sensor. Examples include attenuation due to signal blockage and variations due to tag orientation. The dominant factor, however, is an effect called “multipath” which is a factor in all location system types, and so is worth a short aside to aid in understanding.

When a tag emits a signal, that signal is, by design, emitted in all directions so as to reach as many sensors as possible. This scattergun signal will bounce off any reflective surface, such as metal objects, and a single sensor may hear the signal from one tag echoing off multiple surfaces. The effect is exactly the same as voice echoes heard when shouting in a large cavern or in the mountains.

In a manufacturing environment, which is filled with metallic objects, the chief concern of location systems is to cope with the damaging effects of multipath. For signal strength systems multipath can be very damaging indeed due to an effect known as signal cancellation.

A radio wave is just like a wave on the ocean: an undulating surface which moves along at a certain speed (the speed of light in the case of radio waves). In the ocean, waves can come from multiple directions and when two peaks meet a very large wave can build up locally as the peaks add together. Similarly a peak from one direction can coincide with a trough from another direction and these completely cancel each other leaving no wave at all. The phenomenon is familiar to surfers who understand that waves come in sets: they wait through the periods when the peaks and troughs are cancelling each other leaving very small waves, instead hoping to catch a period of peaks combining with peaks for the biggest surf of the set.

The exact same signal cancellation phenomenon affects radio waves as they bounce off multiple reflectors and arrive at a sensor from many directions. The adding and cancelling of peaks and troughs look to the sensor like increases and decreases in signal strength, which that sensor interprets as decreases and increases in tag range even though the tag may not be moving at all. The result is that the error bands in Figure 4-5 can grow very wide due to multipath, causing large errors in tag location.

Wednesday, January 01, 2014

The Golden Rule: Better Visibility = Better Process

Without Ubisense you can't see the entire picture....
Visibility is a critical component in any task that involves motion. Humans rely on their sense of sight, sound, touch and even smell in order to identify and locate objects around them, and in doing so safely and efficiently complete execute tasks involving intricate motion. The seemingly simple task of walking through a crowded shopping mall requires detailed knowledge of the position, nature and motion of all objects in that environment lest we expect a wall to move out of our way, or needlessly dodge a person whose path does not in fact cross ours.


But with Ubisense you can see exactly where everything is in real time. 
Any manufacturing process is similarly a complex task involving intricate motion: parts and sub-assemblies move from suppliers to assembly facilities; items under construction move from workstation to workstation; tools, parts and workers must assemble at the right place at the right time. The list goes on and on.

In any such environment the scope for mistakes and inefficiencies is prevalent: parts delivered to the wrong place, the incorrect tools used, bottlenecks impeding progress, items lost. In just the same way that human senses provide real-time information about the environment enabling informed judgments to be made and efficient progress to follow, location intelligent systems provide visibility into manufacturing processes and give operators the visibility and control needed to optimize efficiency and eliminate mistakes.





Tuesday, November 26, 2013

5 Steps to an Irrefutable ROI Report



Ubisense is keenly aware that time is valuable and each day that an organization operates without a tracking system means thousands of dollars lost due to operational inefficiencies. You need hard numbers to justify the spend internally but you don’t have time to tackle the research in addition to your day job. We get it and we can help you. We’ve developed a five step process that enables us to gather the information we need to deliver an irrefutable ROI report so you can get what you need.  

Here’s our five-step process:

Step 1: Understand the process or processes that require improvement. Any existing data, such as value stream maps or efficiency studies, are reviewed if available.

Step 2: Ubisense visits your site to review the process(es) that require improvement in detail. The best starting point for this review is a physical walkthrough of the process (es) typically with the person who oversees the department. During this walkthrough, a critical Q&A session occurs to understand every aspect of the process(es), including all the ways things don’t go according to plan.

Step 3: On the same day, we regroup in a conference room and walk through the process(es) again, referring to a facility map, taking copious notes on process flow and gathering as many metrics as are available.

Step 4: The final stage of the site visit is to understand the financial terms for how operational efficiency is measured, and whether any specific company goals are being pursued. From this on-site visit, we learn about the great variability and customization of each individual product that makes the customer’s manufacturing process highly complex and difficult to manage.

Step 5: Ubisense delivers an irrefutable ROI report that includes the hard numbers and timeframe specific to your business operations, and you have the proof you need to gain purchasing approval



Tuesday, October 29, 2013

Streamlining Manufacturing

The small plastic tags developed by a University spin-out are helping make modern assembly lines up to ten per cent more efficient, by tracking hundreds of components in three dimensions and in real time.

Getting the maximum visibility over what’s happening in a plant allows for maximum improvements in quality and process speed.
Andy Ward
Tracking technology developed by Cambridge company Ubisense can greatly improve the accuracy and reliability of manufacturing lines, while reducing assembly times by up to ten per cent, by determining the exact coordinates of an item within a given space.
Ubisense, which spun-out from the University’s Computer Laboratory in 2002 and went public in 2011, has developed a highly-sensitive real-time tracking system, which decreases losses and increases efficiency in the manufacturing sector. The company’s products are used by more than 500 companies in 50 countries worldwide, including major companies such as BMW and Airbus.
The assembly line which Henry Ford envisioned, where “any customer can have a car painted any colour that he wants so long as it is black,” is a world away from modern lines. Today, purchasing a car involves a head-spinning number of options, from paint colour to engine size to satnav. While this is a plus for the consumer, it has made assembly lines vastly more complicated, where each car on the line is different than the one ahead of it, meaning that tool settings must be manually changed for each car. Ubisense’s technology can improve accuracy while reducing assembly time by as much as ten per cent, automatically adjusting tool settings so that the correct settings are always used on the correct car.
The technology was developed by Andy Ward while he was a PhD student at the Computer Laboratory. Dr Ward, who is now Ubisense’s Chief Technology Officer, originally devised a system to track individuals as they moved around the Lab.
“This was in the mid-1990s, before most people had mobile phones,” he says. “At the time, it was considered totally revolutionary, because you could find out where your colleagues were without having to play phone tag. But we soon figured out that not only could you reroute phone calls, you could do lots of other interesting things too: computer systems in the building could alter the way that they worked based on who was near them and what was going on around them.”
After leaving the University, Ward co-founded Ubisense and set out to develop a more accurate version of his tracking system, which could not only determine which room an individual or piece of equipment was in, but also exactly where they were located in that room, what equipment was nearby and what that equipment was doing.
Ubisense’s system can be likened to a super-charged radio frequency identification (RFID) tag. RFID tags, such as those found in Oyster cards, send out a signal when it reaches a particular point, such as a card reader, but Ubisense’s system allows for highly precise, continuous tracking. The radio-based system consists of transmitters embedded in small tags, roughly two centimetres square, and base stations installed around a building.
As a tagged item moves through a space, the base stations will identify its precise coordinates in real time. Where RFID is useful in applications such as inventory control, the Ubisense system is ideal for manufacturing lines, where many different component parts need to come together at a certain point in time.
For example, the company has recently established a relationship with Airbus. Although Airbus builds its aeroplanes in Toulouse, the major component assemblies (MCAs) of the planes are constructed at facilities all over Europe. As Airbus does not have storage in Toulouse for huge stockpiles of aeroplane parts, all of the MCAs must arrive in Toulouse together. Airbus tags the MCAs with Ubisense technology, so that Toulouse can track their progress in factories across Europe to ensure that they all arrive in Toulouse at the same time, where they are bolted together and the finished aeroplane is flown off.
In addition to Airbus, the Ubisense technology is used by BMW in several of its car factories, saving time by ensuring that the settings on the various tools used on the line are automatically adjusted as an individual worker moves from car to car along the line. Industry estimates that the Ubisense technology can cut assembly time for each car by as much as ten per cent.
“The goal of the technology is to get the most accurate view of what’s happening, because then the computer can make the most sensible decision about what to do next,” says Dr Ward. “We’re trying to build systems which reduce the amount of human interaction which is required. By taking people out of the loop, you can make a system more error-proof. Getting the maximum visibility over what’s happening in a plant allows for maximum improvements in quality and process speed.”
In just over a decade, the company has grown from four staff to nearly 200, and in addition to its head office and research facilities in Cambridge, it has offices in Paris, Dusseldorf, Denver, Singapore and Seoul.
The company maintains links with the Computer Laboratory, where it originated, collaborating on various research projects. Its technology is manufactured in the UK, at a facility in Bedford.
Ward says it was the characteristics of the Cambridge Cluster which enabled the company to get off the ground in the first place. “Everything we needed to build a successful company was right here, because Cambridge is such an interesting mix of industrial know-how, funding opportunities and academic expertise.”
For more information, contact sarah.collins@admin.cam.ac.uk. 
- See more at: http://www.cam.ac.uk/research/features/streamlining-manufacturing#sthash.ZQuA7nH5.dpuf