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Automate with Apex

Automate with Apex. Scott Dugan SDugan@commandalkon.com 913-384-0880 Ext. 5767. Session Objective. Learn how automation can reduce truck time in the plant, streamline your vehicle ID and scale ticketing process, and make your operation more efficient and cost effective. 

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Automate with Apex

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  1. Automate with Apex Scott Dugan SDugan@commandalkon.com 913-384-0880 Ext. 5767

  2. Session Objective • Learn how automation can reduce truck time in the plant, streamline your vehicle ID and scale ticketing process, and make your operation more efficient and cost effective.  • This session will highlight products that you can integrate with your Apex application to improve your daily operations, with a focus on real world case studies that include unattended and remotely attended sites. • Also learn more about Scale Watcher, which provides photo verification of the vehicle weighing process, and the anti-theft options that are available with this module. This session will challenge you to rethink current processes to make room for site improvements. BLK-005 Automate with Apex

  3. Session Outline • Why Automate? • Technology Overview • What does Apex have to offer? • Dividia Presentation • Study Abroad (Real World Example) • A look at other industries • Project Implementation Approach BLK-005 Automate with Apex

  4. Why Automate • Customer Service • Reduced Time In Plant • Reduced Stress from Trucks Lined up • Ticketing Accuracy • After Hours Access • Accommodate Spikes in Demand • One Time Job? • Safety • Keep drivers in the truck BLK-005 Automate with Apex

  5. Why Automate • Operational Efficiencies • Increase throughput over scale • Semi-attended and unattended operations • Improved utilization of staff • Freed up for other tasks • Less Re-work – Overloads / Underloads BLK-005 Automate with Apex

  6. Scott Killough’s Childhood “Scott, is that a remote control for the lawn mower?” “No Dad, the mower is fully automated. I’m just downloading historical data to calculate my allowance.” Scott Killough BLK-005 Automate with Apex

  7. Technology Overview From Check In To Loading To Ticketing BLK-005 Automate with Apex

  8. Technology Overview From Check In To Loading To Ticketing BLK-005 Automate with Apex

  9. Automating the Check-In Process • Why Check In? • Know which trucks are in your plant • Solve any issues up front (Credit, Expired Tare, etc.) • Facilitates more efficient loading and check out • Track Time in Plant for improvements • Check in options defined by vehicle • Pre-Assigned to a Load • Apex Dispatch Module • Manual Assignments by Weighmaster • Repeat Last Load • Driver selects from authorized choices • Apex RFID Terminal • Apex RFID Kiosk BLK-005 Automate with Apex

  10. RFID Technology • Automated vehicle identification • Eliminates errors caused by keying in wrong Truck ID • Truck mounted or • Hand held tags • Readers can be placed in multiple locations to automate different process steps in the plant. BLK-005 Automate with Apex

  11. RFID • Truck mounted tags • Similar to Toll Pass • Higher cost • Ideal for a fairly static fleet • Fastest ID (just drive past like highway toll) • Extremely efficient for ID Only stations (No driver interaction) BLK-005 Automate with Apex

  12. RFID • Hand Held Tags • Lowest Cost • Ideal for larger dynamic fleets • Requires driver to stop and present card. • Flexibilty for situations where you might issue more than one card BLK-005 Automate with Apex

  13. Driver Interfaces • Traffic Lights • Less confusion and faster processing of trucks • Gives simple indication of success/error at check-in and ticket out. • Eliminate verbal communication and premature drive offs. BLK-005 Automate with Apex

  14. Driver Interfaces • Setup Examples • Multiple lights with lane/silo indicators. • Example: Check Vehicle in Plant • Truck pulls on scale and views red light. Upon selection of load information a light is turned on indicating which lane or silo to proceed to for loading. C Proceed Lane/Silo “C” BLK-005 Automate with Apex

  15. Driver Interfaces • Auxiliary Display – Configurable Messages Welcome to Apex Quarry Proceed to Stockpile Area 2 BLK-005 Automate with Apex

  16. Driver Interfaces • Present RF Card and respond to prompts for authorized selections. BLK-005 Automate with Apex

  17. Driver Interfaces • Touch Screen Interface • Provides familiar intuitive user interface. • Allows driver to select from multiple lists • Provides clear way to confirm current assignment • Options to enter additional info BLK-005 Automate with Apex

  18. Driver Interfaces • RFID Kiosk BLK-005 Automate with Apex

  19. Driver Interfaces • The RFID Kiosk integrates the most common needs into one plug and play packaged solution. • RFID • Sunlight Readable Touch Screen Interface • Digital I/O (Traffic Lights, Sensor Inputs, etc.) • Aux Display Option • Single Ethernet connection for all devices • Thermostat controlled NEMA enclosure BLK-005 Automate with Apex

  20. Driver Interfaces BLK-005 Automate with Apex

  21. Driver Interfaces BLK-005 Automate with Apex

  22. Driver Interfaces BLK-005 Automate with Apex

  23. Technology Overview From Check In To Loading To Ticketing BLK-005 Automate with Apex

  24. Automating the Loading Process • Wireless Loader Notification • Driver or Operator initiated overhead loading • 3rd party PLC loading (on-the fly blending) BLK-005 Automate with Apex

  25. Wireless Loader • Provides the loader operator with a real time display of trucks in plant. • Eliminate ‘lost’ trucks and product errors caused by verbal communication. BLK-005 Automate with Apex

  26. Wireless Loader • Can utilize plant wireless network or cellular ‘aircard’ for connectivity. • Communicates with ‘service’ that resides on the same LAN as Data, allowing for network ‘dead’ spots. BLK-005 Automate with Apex

  27. Wireless Loader BLK-005 Automate with Apex

  28. Wireless Loader • Capture Load Times for Statistical Analysis • More detailed view of in yard times • Track averages by product, time of day, etc. BLK-005 Automate with Apex

  29. Loadout • Controls single or multiple overhead silo gates or spouts to load asphalt, aggregate, or cement into trucks and rail cars. • Apex Loadout • 3rd Party Loadout BLK-005 Automate with Apex

  30. Apex Loadout • PLC based loadout control with support for Silos over Scale, Negative Weigh, and Weighbatchers • Load profiles by vehicle type • Support for short scale scenarios • Auto learn for consistent accuracy • Driver initiated self-load option • Can integrate RFID to ‘auto-populate’ Loadout operator screen BLK-005 Automate with Apex

  31. Apex Loadout Screen Components

  32. Apex Loadout – Silo Inventory

  33. Apex Driver Initiated Loadout • RFID at Lane Entrance • Strobe Light on Silo • Pull cord to Initiate Drop • Traffic Lights Direct Driver Through Process BLK-005 Automate with Apex

  34. 3rd Party Loadout • Standard interface to 3rd party Loadout systems • PLC Interface • Database (WEM/Libra) Interface BLK-005 Automate with Apex

  35. 3rd Party Loadout - WEM

  36. Technology Overview From Check In To Loading To Ticketing BLK-005 Automate with Apex

  37. Automating the Ticketing Process • RFID of vehicle at Outbound scale • Most ticketing should be completely self service • Consider off-site clerk for some locations • Remote ticket printing • Special handling (i.e Cash) can be directed to alternate printer • Scale Watcher • Integrated video capture solution for providing photo verification and event notification BLK-005 Automate with Apex

  38. Remote Ticket Printing • Easiest way to reduce time on scale • Ideally 1 truck length way • Driver stays in truck and out of scalehouse • Can be used with automated or manual ticketing. BLK-005 Automate with Apex

  39. Video Capture • Integrated video capture solution for providing photo verification and event notification of the weighing process. BLK-005 Automate with Apex

  40. Real World Examples BLK-005 Automate with Apex

  41. Real World Examples Kiosk and Traffic Lights Check In Wireless Loader Loading ID Terminal & LED Sign Ticket Out Scale Watcher Remote Printer 41

  42. Order Taking and Dispatch

  43. In Bound BLK-005 Automate with Apex

  44. Out Bound BLK-005 Automate with Apex

  45. Retrieve Ticket BLK-005 Automate with Apex

  46. Real World Examples “Before Apex was trialed, manually recorded times demonstrated that trucks spent 24 minutes in the quarry. Today, through the utilization of Apex, that time has been reduced to 14 minutes.” BLK-005 Automate with Apex

  47. Project Planning • Define Goals • Review / Define Complete Process • Process Narrative • Document Exception Handling • Sell the Plan (Early Buy-In) • Go-Live Training Plan (Users/Drivers) BLK-005 Automate with Apex

  48. Summary • One solution does not fit all locations • RFID and Remote Printing are biggest bang for the buck – low hanging fruit • Yes, even your truck drivers can use these systems • Involve us early in the process – leverage our experience BLK-005 Automate with Apex

  49. The End Join us in the Trade Show area for a full demonstration. BLK-005 Automate with Apex

  50. Please Complete Your Evaluation • Be sure to circle the session you are evaluating on the back of your card • Track Name: Bulk Materials • Session Code: BLK-005 • Session Title: Automate With Apex • All breakout session materials can be accessed at: www.commandalkon.com/cc2012/update/index.htm • Thank You! BLK-005 Automate with Apex

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