RTLS Applications and Case Studies
Manufacturing
Process & Energy
Public Transport
Agriculture
Military
Events & Entertainment
Logistics
Research & Other
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
BMW Car Plant Regensburg, Germany
Military
Events & Entertainment
Other
(Final Assembly Tool Assistance)
Installed area: 1.7 km assembly line | Sensors: 350 | Accuracy: 30 cm in 3D | Events/day: 150000 | Reliability: 99.99%
Problem
Different models of car are produced on the same line necessitating loading a different
tool program into the power tools based on the specific vehicle to be worked upon.
Previously the identification of the vehicle occurred using a barcode scanner resulting in
unproductive work (~6 seconds per tool op. at 150 tool stations on 1,000 cars per day).
The Ubisense solution
Production Management System
Ubisense
Tool Assistance
IBS Tool
Controller
Vehicle - Tool
association
DC Tooling
The Ubisense system tracks both vehicles and tools detecting when a tool is brought
close to the vehicle. The required tool program is obtained from the MES using the VIN
and sent directly to the IBS Tool Controller to program & enable the tool. The system
solution was jointly developed by Ubisense and IBS.
Result
Cost and time reduction on the line and quality improvement by excluding human error
and re-work. Unproductive time saved reduces costs by many $100,000‘s.
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Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Aston Martin Car Plant Gaydon, UK
Agriculture
Military
Events & Entertainment
Other
(Finishing Process Tracking)
Installed area: 11700 m² | Sensors: 58 | Accuracy: 50 cm in 2D | Reliability: 99.9%
Problem
As cars come off-line into the finishing area, they can miss process steps leading to
rework or become ‘stuck’ in a step creating inventory build up.
The Ubisense solution
The Ubisense system tracks the vehicles as they come ‘off-line’ and move through
specific process stages (rolling road, wheel alignment, paint inspection, etc.). Defined
rules specify the process order and dwell time thresholds (time spent in a step).
Exceptions trigger alerts visible to shop-floor operators and reported on intranet.
Enterprise Intranet
Ubisense
Process Tracker
Result
Time reduction and Work In Progress (WIP) throughput improvement as cars are
always visible through the finish and rework process. Reduced rework and improved
quality.
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Vehicle - Bay /Area association &
process rules
Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Honda Motorcycle Plant Atessa, Italia
Agriculture
Military
Events & Entertainment
Other
(Component Process Tracking)
Library Images
Installed area: 2000 m² (75 m assembly line) | Sensors: 13 | Accuracy: 30 cm in 3D | Reliability: 99.9%
Problem
The production process required manual barcode scanning of printed VIN labels at each
station in order to call up the specific task list. In addition, there was no traceability of
major components.
The Ubisense solution
IBM LAS
Ubisense
Location Platform
Passive
RFID
Motorcycle &
Components Tracking
Frame
Identification
The Ubisense system tracks vehicles on the line enabling automatic identification of
required tasks at each station (via interface with Production Planning System). In
addition, major components are tracked and associated with specific vehicle to provide
automatic traceability and replenishment signaling.
Result
Process optimization and error reduction on the line has increased productivity and
quality. In addition inventory replenishment has been improved and component
traceability means long term quality and customer satisfaction will be improved.
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Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
Ortrander Iron Foundry Ortrand, Germany
Military
Events & Entertainment
Other
(Material Flow Tracking)
Installed area: 2000 m² | Sensors: 11 | Accuracy: 30 cm in 3D | Reliability: 99.9%
Problem
The content (number and type of part, status in production cycle) and location of containers
was not visible centrally in the production control system. This resulted in delays fulfilling
customer orders since it was not known whether or not sufficient quantities of completed
parts were available.
The Ubisense solution
Ortrander PPS
Ubisense
Location Platform
Passive RFID &
Weighing Sys.
Forklift Tracking
Material Identification &
Weighing
The Ubisense RTLS continuously tracks forklift movements whilst the Spatial Platform maps
processing stations and storage locations as hot-zones and combines these with the pallet
ID determined via passive RFID reader and the results of the on-fork weighing system. As
pallets are slotted the PPS is informed, so it knows the specific ID and location of pallets at
all times and can update the process stages of orders automatically in real-time.
Result
Increased productivity, reduced cost & dwell time, faster fulfillment of customer orders.
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Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
Military
Caterpillar Equipment Plant Gosselies, Belgium
Events & Entertainment
Other
(Assembly Tool Control)
Installed area: 400 m² | Sensors: 8 | Accuracy: 30 cm in 3D | Reliability: 99.9%
Problem
The assembly of the hydraulic valves at the heart of Caterpillar construction vehicles is
performed using torque wrenches to fasten reinforced tube hoses to the valves. The
tightening of a bolt that fastens a hose to a valve must be applied with a specific amount
of torque – around 300 Newton meters (Nm) – in order for that valve to operate properly.
Caterpillar’s quality standards demand 100% traceability of correctly tightened hoses.
DeJaeger Protrac (PMS)
Ubisense
Location Platform
DeJaeger
Tool Control
Valve - Tool
association
DC Tooling
The Ubisense solution
The Ubisense system tracks wireless electronic wrenches, detecting when the tool is
brought close a valve assembly station. Each wrench is designated for a specific assembly
station, and is preset to tighten a specified amount. The location information ensures that
each wrench is being used at the correct station when the quality data is collected.
Result
Increase in correctly assembled valves and hoses leading to less rework on leaking valves.
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Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
Bath Iron Works Shipyard Maine, USA
Military
Events & Entertainment
Other
(Asset Management)
Installed area: xxx m² | Sensors: 54 | Accuracy: 100 cm in 3D
Problem
Finding / tracking assets and tools on the dock and inside buildings. Assisting in the completion
of audits for government owned equipment
The Ubisense Solution
Long range sensors tracking tagged assets between ships. Combination of wired and wireless
sensors working indoors and outside in very harsh conditions
Enterprise Intranet
Ubisense
Asset Tracker
Accuracy delivered 1 – 1,5m
Results
Improve efficiency by reducing search times. Improve production times and reduce time to
complete government audits
Asset & Tool Tracking
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Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
Cummins Engine Plant Jamestown, USA
Military
Events & Entertainment
Other
(Test Process Monitoring)
Installed area: xxx m² | Sensors: 76 | Accuracy: 30 cm in 3D | Reliability: 99.9%
Problem
Searching for engines throughout the repair, test and shipping areas was taking too long
and slowing down production cycle time and requiring extra staff.
The Ubisense Solution
Tags are scanned, associated with and attached to engines as they enter the repair or
shipping areas. Engines then are tracked and every time an engine enters or exits a work
cell the exact time is recorded in a standard database and passed into the Allen-Bradley
PLC. In addition their location can be determined via a web browser.
Allen-Bradley PLC
Ubisense
Process Tracker
As engines leave the plant, tags are removed in the shipping office and automatically
disassociated from the engines they had been attached to.
Result
Continuous automated monitoring processes leading to higher throughput. Search time for
engines has dramatically decreased (in the repair area search time has decreased by 98%)
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Engine - Bay /Area association &
process rules
Case Study © by Ubisense 2009
Manufacturing
Process &
& Energy
Energy
Process
Public Transport
SMDK Kölliken, Switzerland
Logistics
Agriculture
Military
Events & Entertainment
Other
(Personnel Security)
Installed area: 11000 m² in phase 1 | Sensors: 42 | Accuracy: 100 cm in 3D
Problem
At the toxic waste dump in Kölliken (SMDK), chemicals are leaking into the groundwater and
threatening the drinking water supply. Therefore the local government ordered the complete
dismantling of the dump which is being carried out in 2 phases. As contaminated materials are
removed, a “black” area had to be erected, consisting of a hall preventing the escape of toxic dust,
gas and odours. Worker safety is a primary concern and escape tunnels proved impractical for both
engineering as well as cost reasons.
Ubisense
Location Platform
The Ubisense Solution
Each worker wears a Ubisense Tag on their helmet. The tracking system enables the Arge Phoenix
management to know the precise whereabouts of all workers within the site's "black" areas so it can
maintain a precise head count in case of a fire or other emergency, and rescue any employees
having difficulty escaping to safety.
Personnel Tracking
Results
Greatly improved worker safety in the “black” area.
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Case Study © by Ubisense 2009
Manufacturing
Process &
& Energy
Energy
Process
Public Transport
Logistics
Areva NP Archive Erlangen, Germany
Agriculture
Military
Events & Entertainment
Other
(Personnel Security)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Automated Alarm
Manual Alarm
Alarm System
Acoustic Equipment
Optical Equipment
Gas Container
Nozzles
Installed area: 1800 m² divided up into several rooms | Sensors: 34 | Accuracy: 100 cm in 2D
Problem
Plans and related building documents for nuclear reactors are stored in the Areva NP central archive for
up to 90 years in acc. with government regulations related to nuclear facilities. In order to prevent loss
or damage from the use of conventional extinguishers, a system is installed which floods the archive
with nitrogen in case of fire. In such a situation, it is imperative to be able to immediately locate all
personnel currently in the archive precisely and reliably to facilitate rapid rescue and evacuation.
Ubisense
Location Platform
The Ubisense Solution
Visitors and employees are registered and supplied with a Ubisense tag upon entry into the archive.
The integrated Ubisense 3D Visualization provides a graphical indication of where the personnel are at
all times. In addition an associated list is maintained, displaying in real-time exactly in which areas how
many staff are located.
Personnel Tracking
Results
Greatly improved worker safety in the archive.
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Case Study © by Ubisense 2009
Manufacturing
Process &
& Energy
Energy
Process
Public Transport
Logistics
Agriculture
BNFL Nuclear Power Facility Sellafield, UK
Military
Events & Entertainment
Other
(Personnel Security)
Installed area: 100 m² | Sensors: 8 | Accuracy: 30 cm in 3D
Problem
Sellafield is one of 20 aging U.K. nuclear facilities being decommissioned. Employees
involved in decommissioning and clean-up within the facility are exposed to fluctuating
radiation. It is vital to ensure that the amount of radiation to which they are exposed
during any one work period remains below the specified limits.
The Ubisense Solution
BIL Solutions
Ubisense
Location Platform
Radiation
Dosimeters
Personnel Tracking
Radiation
Measurements
Employees carrying out work assignments at the power plant wear both Ubisense Tags
and WiFi dosimeters, which measure radiation levels. BIL Solutions' software provides
views of the facility, with radiation levels depicted in different colors combining location
data from the Ubisense RTLS with the radiation readings. Workers' dose histories are
monitored real-time as an aid to scheduling their work in the plant.
Results
The radiation maps and real-time exposure records significantly improve worker safety
and efficiency of the operation.
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Case Study © by Ubisense 2009
Manufacturing
Process &
& Energy
Energy
Process
Public Transport
BP Refinery, Germany
Logistics
Agriculture
Military
Events & Entertainment
Other
(Personnel Safety Pilot Installation)
Installed area: Perimeter around 22000 m² | Sensors: 22 | Accuracy: 150 cm in 2D
Problem
Safety monitoring of personnel in hazardous environments.
The Ubisense solution
The Ubisense RTLS network covers the perimeter, access paths and strategic internal
junctions and tracks staff wearing tags on their helmets as they walk around the
enclosed area. The Spatial Platform creates hot zones around hazardous plant to
provide visual safety alerts.
Ubisense
Location Platform
Result
Real time location visibility and zone-level monitoring of personnel
Automatic notification of unauthorised entry into safety critical zones
Increased safety and process compliance
Personnel
Tracking and Identification
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Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
VBL Bus Depot Luzern, Switzerland
Agriculture
Military
Events & Entertainment
Other
(Depot Management)
Installed area: 15000 m² in 1 depot | Sensors: 48 | Accuracy: 100 cm in 2D | Reliability: 99.9%
Problem
Management of the workflow in a bus-depot is an important issue today. Knowing, if a bus
enters or leaves a depot as well as the position of the each bus inside a depot is
fundamental for efficient planning and dispatching.
The Ubisense Solution
Swiss Axis BeDips
Ubisense
Location Platform
Each of the 160 buses of vbl is tagged, allowing the Ubisense platform to determine time
stamps of incoming and outgoing buses and an exact bay, lane, and position of each bus, as
soon as it is parked inside the garage. The online-interface to the Swiss Axis BeDips Depot
Management System enables dispatchers to efficiently schedule and organise the parking,
maintenance and refuelling processes in the depot.
Results
Correct, fast and reliable dispatching, correct invoicing of the work in a depot (maintenance,
cleaning and preparation for the daily use)
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Bus
Tracking and Identification
Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
JeNah Bus & Tram Depots Jena, Germany
Military
Events & Entertainment
Other
(Depot Management)
Installed area: xxx m² over 2 depots | Sensors: 104 | Accuracy: 100 cm in 2D | Reliability: 99.9%
Problem
Management of the workflow in tram and bus depots is an important issue today. Knowing,
if a vehicle enters or leaves a depot as well as the position of the each vehicle inside the
depots is fundamental for correct dispatching, maintenance planning and invoicing.
The Ubisense Solution
VAB Depot Management System
Ubisense
Location Platform
Each of the 40 trams and 135 buses of JeNah is tagged allowing the Ubisense platform to
determine time stamps of incoming and outgoing vehicles and an exact bay, lane, and
position of each vehicle, as soon as it is parked in- or outdoors in one of the depots. The
online-interface to the Depot Management System of Verkehrsautomatisierung Berlin (VAB)
enables the dispatchers to take better decisions and operate more efficiently.
Results
Correct, fast and reliable dispatching, correct invoicing of the work in a depot (maintenance,
cleaning and preparation for the daily use)
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Bus and Tram
Tracking and Identification
Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
Metro Transit Bus Depots Minneapolis, USA
Military
Events & Entertainment
Other
(Transit Yard Management)
Installed area: xxx m² over 5 garages | Sensors: 450 | Accuracy: 100 cm in 2D | Reliability: 99.9%
Problem
Buses were being manually located and their location input into the Scheduling and
Dispatching System using a paper mark-up sheet which was never up to date.
Enterprise Intranet
The Ubisense Solution
Ubisense
Transit Yard Manager
Each bus of the 1000 buses of Metro Transit is tagged allowing the Ubisense platform to
determine an exact bay, lane, and position of each bus, as soon as it is parked inside the
garage and in some outdoor areas. Dispatchers have real time visualization of vehicles for
assignment.
Results
Elimination of need for dedicated search personnel in each of the five Metro Transit garages.
Faster and more reliable information about bus location
Assistance in determining bus departure and arrival times and time spent in maintenance
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Bus
Tracking and Identification
Case Study © by Ubisense 2009
Manufacturing
Process & Energy
Public Transport
Logistics
Agriculture
Military
Events & Entertainment
Other
www.ubisense.net
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Case Study © by Ubisense 2009