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Automate with Apex. Allen Bryant abryant@commandalkon.com 913-384-0880 ext.5724. 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. Why Automate
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Automate with Apex Allen Bryant abryant@commandalkon.com 913-384-0880 ext.5724
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. • Why Automate • Technology Overview • Real World Examples • Project Planning BLK-006 Automate with Apex
Why Automate • Site automation is an essential component in an overall process improvement strategy. • Issues and opportunities are unique to a location, but several common solutions can be applied. • The total return on investment is typically the sum of several small improvements and efficiencies realized. BLK-006 Automate with Apex
Why Automate • Customer Service • Time In Plant • Ticket / Invoice Accuracy • Before/After Hours Access • Recordation / Reporting • Safety • Keep drivers in the truck BLK-006 Automate with Apex
Why Automate • Operational Efficiencies • Increase throughput over scale • Improved utilization of staff • Semi-attended and unattended operations • More adaptable to fluctuating demand • Load accuracy (Physical and Data) BLK-006 Automate with Apex
Technology Overview From Check In To Loading To Ticketing BLK-006 Automate with Apex
Technology Overview From Check In To Loading To Ticketing BLK-006 Automate with Apex
Automating the Check-In Process • If at all possible, deal with the trucks on entrance • RFID of vehicle at Check In • Check in options defined by vehicle • Pre-assigned or Dispatched (no interaction – green light to load) • Driver selects from valid choices at check in station (RFID Terminal or Kiosk) • Scale clerk sees vehicle info and completes assignment BLK-006 Automate with Apex
RFID • RFID technology for automated vehicle identification • Hand held or truck mounted tags • Eliminates errors caused by keying in wrong Truck ID • Readers can be placed in multiple locations to automate different process steps in the plant. BLK-006 Automate with Apex
RFID • Truck mounted tags • Higher cost • Ideal for a fairly static fleet • Fastest ID (just drive past) • Extremely efficient for ID Only stations (No driver interaction) BLK-006 Automate with Apex
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-006 Automate with Apex
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-006 Automate with Apex
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. BLK-006 Automate with Apex
Driver Interfaces • Auxiliary Display BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces • Present RF Card and respond to prompts for authorized selections. BLK-006 Automate with Apex
Driver Interfaces • I/O Wired to RFID Terminal Photo Eye Inputs Traffic Light Outputs BLK-006 Automate with Apex
Driver Interfaces • Cost effective solution for sites with simple driver interaction needs. BLK-006 Automate with Apex
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-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces • Raw Material Inbound Ticket # BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces BLK-006 Automate with Apex
Driver Interfaces • RFID Kiosk BLK-006 Automate with Apex
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-006 Automate with Apex
Technology Overview From Check In To Loading To Ticketing BLK-006 Automate with Apex
Automating the Loading Process • Wireless Loader Notification • Driver or Operator initiated overhead loading • 3rd party PLC loading (on-the fly blending) BLK-006 Automate with Apex
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-006 Automate with Apex
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-006 Automate with Apex
Wireless Loader BLK-006 Automate with Apex
Wireless Loader • Capture Load Times for Statistical Analysis • More detailed view of in yard times • Track averages by product, time of day, etc. BLK-006 Automate with Apex
Loadout • Controls single or multiple overhead silo gates or spouts to load asphalt, aggregate, or cement into trucks and rail cars. BLK-006 Automate with 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-006 Automate with Apex
Driver Initiated Loadout • RFID at Lane Entrance • Strobe Light on Silo • Pull cord to Initiate Drop • Traffic Lights Direct Driver Through Process BLK-006 Automate with Apex
OPC Interfaces • Standard interface to 3rd party PLC based loadout and blending controls • Interface to Misc I/O devices (Gates, Photosensors, etc). BLK-006 Automate with Apex
OPC Interfaces • Standard interface to 3rd party PLC based loadout and blending controls • Interface to Misc I/O devices (Gates, Photosensors, etc). BLK-006 Automate with Apex
Technology Overview From Check In To Loading To Ticketing BLK-006 Automate with Apex
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-006 Automate with Apex
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-006 Automate with Apex
Offsite Scale Ticketing BLK-006 Automate with Apex
Video Capture • Integrated video capture solution for providing photo verification and event notification of the weighing process. BLK-006 Automate with Apex
Real World Examples BLK-006 Automate with Apex
Real World Examples • Primary Objective – Reduce time in plant BLK-006 Automate with Apex
Real World Examples Antenna (LAN Connection) Wireless Repeater Truck Scale Check In Station (Touchscreen) RFID Reader BLK-006 Automate with Apex
Real World Examples • Results • In yard times are now consistently 10-15 minutes as compared to 30 – 60+ minutes before implementation. • Increased business as a direct result. • Provide regular reports on in-yard times, by truck, to primary carriers. BLK-006 Automate with Apex
