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[RFID Newsletter, March 23, 2011] Herma, a German adhesive label manufacturer, has implemented a real-time positioning system since June last year. The daily volume of pallets has increased by 67%, and 500 can be transported a day. The pallets also reduced shipping errors reported by monthly customers, from 50 errors to seven. The solution to help the company improve efficiency and reduce errors was provided by Ubisense, which was implemented by tracking forklift trucks that transport pallets.
Herma is based in Filderstadt, Germany, and is one of the world's largest label manufacturers, and the company's self-adhesive product output continues to increase for offices, schools, printers and homes. The company sells its products to customers around the world in the form of large rolls. When transporting the product, these reels (which are typically a few feet in size) are packed into trays and stretched. Next, a bar code label is attached to the stretch package around each tray, and then scanned to match the tray to the specific product and the order to be filled. This pallet is moved several times in the warehouse until the truck comes to deliver the goods.
In order to ensure the correctness of the pallet and to ensure that the pallet is loaded with the correct truck, the forklift driver uses the hand-held scanner to read the barcode label of the pallet, and then the driver compares this number with the number printed on the order (RFID RF Express Note) : For backup, the same readable serial number is printed on each barcode label).
According to Holger Hartweg, Herma's account manager, in 2009, Ubisense and Herma discussed an automated solution that used Ubisense's battery-powered RFID tags to help Herma's staff locate the loaded pallets and ensure that they were correct. The product was loaded on the right truck. He explained: "We think that labels are placed on each tray, and every time the trays are shipped from the manufacturing facility, we can read the labels." However, installing Ubisense's battery-powered labels on each tray is expensive. And the label can't be returned if it is shipped out. He said: "We need a good way to return the label on the tray, but did not think of any way."
So Ubisense and Herma came up with a new plan: use Ubisense's RFID tags and readers to track the position of the forklift with the pallets, and record where the pallets in the warehouse were picked up and lowered. This will let you know the location of the product. The final solution consisted of installing 24 Ubisense readers on the ceiling of a 500-square-meter warehouse, and installing four Ubisense tags and a terminal with a display on each of the seven forklift trucks to provide the driver with the driver. Instructions for use and location data. Ubisense software handles the flow of information between forklift readers, while Herma's SAP-based back-end software manages the company's order data and the location and identity of each pallet.
With this new system, the forklift driver receives order information on the Ubisense touch screen terminal on the forklift. The touch screen shows the list of required trays and the approximate approximate location of the tray.
When the forklift arrives in front of the designated pallet, the driver uses the handheld barcode scanner to read the pallet label and forward the information over a Wi-Fi connection to the Ubisense software running on the Herma backend ERP system. The bar code serial number on the pallet will be compared to the serial number on the order. If it can be matched, the Ubisense software will indicate the arrival point of the driver's pallet. If the correspondence does not match, an alarm will be displayed on the screen and the driver will continue to search for the correct tray.
After picking up the tray, the driver presses the prompt to indicate that he has started shipping the tray to his destination. Each forklift's Ubisense ultra-wideband (UWB) RFID tag transmits a 6 to 8 GHz ultra-wideband RF signal with a unique ID number that is connected to the ID number of the vehicle in the Ubisense software.
Once the driver has received the designated tray, place it in the designated location (for example, in the standby area waiting for loading). After placing the tray in the designated position, the driver presses a prompt on the screen to indicate that he has delivered the tray as instructed, and the label transmits the signal to a nearby reader. Ubisense software calculates the tray placement based on the reader's data. Location, then this information is linked to Herma's SAP software. Since the forklift is equipped with 4 tags (RFID RF Express Note: installed on each corner of the forklift), it can be positioned within about 30 cm and can determine the orientation, so that the direction of the forklift can be known. Know the location of the tray.
This process is the same when the pallet is ready to be loaded onto the truck. When the driver puts the pallet into the truck, he presses the prompt on the screen. At the same time, the software calculates the position of the forklift to determine which truck is loaded on the pallet.
The truck's label transmits signals at different time intervals. If the tags do not move within the preset time interval, they will go to sleep and stop transmitting signals. When the forklift moves again, the label begins to transmit signals again. If the forklift is at the sorting of the pallet, the signal transmission rate is higher than when the forklift is in a non-critical area.
Herba's logistics and customs manager Frank Baude said: "With this system, the same number of workers, we can ship more pallets, because now it doesn't take so much time to check the ID number and compare the ID number. This efficiency The improvement is crucial. The company and its customers are very satisfied."
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