The goal of the company is the digitization of the individual production steps as well as the most efficient utilization of resources while maintaining quality and safety standards. In line with INTRA<\/strong>NAV Virtual Manufacturing Solutions<\/strong><\/a>, we implemented an RTLS solution that included real-time location, automated workflows interacting with electronic displays, and analysis options.<\/p>\n\n\n\n
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For a global leader for affordable
and sustainable energy<\/h2>\n\n\n\n
The energy company is one of the leading international providers of sustainable, reliable and affordable energy products, solutions and services along the entire energy value chain. In more than 90 countries and with 90,000 employees worldwide, the company supports its customers on their way to a sustainable future.<\/p>\n\n\n\n
Centimeter-precise site localization and process tracking through ultra-wideband-based INTRA<\/strong>NAV.RTLS<\/strong> TAGs, enable digital mapping of the powder manufacturing process.<\/p>\n\t\t\t\t<\/li>\n\t\t\t \t\t\t\t Real-time status updates via E-Ink TAGs:<\/strong> Status, material number, batch number, batch barcode, quantity, SAP material number, number of reuses, powder container, container type.<\/p>\n\t\t\t\t<\/li>\n\t\t\t \t\t\t\t Real-time location and status updates enable platform-based notifications as soon as predefined processes deviate from target values.<\/p>\n\t\t\t\t<\/li>\n\t\t\t \t\t\t\t Event triggers initiate e.g. process blocking, process release or notification for internal transport.<\/p>\n\t\t\t\t<\/li>\n\t\t\t \t\t\t\t INTRA<\/strong>LYTICS provides analytics of all movement and location data to be able to optimize workflows between processes. Such as: Dwell times, idle times, throughput times, trails as structured data export via CSV.<\/p>\n\t\t\t\t<\/li>\n\t\t\t \t\t\t\t Through the interface to the SAP MES, location-based information can be used to lock or unlock processes.<\/p>\n\t\t\t\t<\/li>\n\t\t\t \t\t\t <\/ul>\n\t\t\t \t\t\t \n\t\t <\/div>\n<\/section>\n\n\n\n\n <\/p>\n\n\n\n <\/p>\n\n\n\n The key for monitoring every step of the powder manufacturing process in real-time, reducing manual processes in production and moving to 100% paperless production is to use the INTRA<\/strong>NAV IoT Edge Suite<\/a> in collaboration with E-Ink Labels<\/a><\/strong>.<\/p>\n\n\n\n \u25cf Powder handler creates new batches in MES<\/p>\n \u25cf Within an interval of 30 seconds, the e-ink is updated with the new batch information (material number, batch number, batch barcode, quantity, batch status, container ID).<\/p>\n Alternative by a manual update: The powder plater hits the function key of the e-ink and thereby triggers the update of the e-ink content.<\/strong><\/p>\n \u279c Process assurance by INTRA<\/strong>NAV: If RTLS could not find the correct container ID from the system for the batch number (due to incorrect entry), INTRA<\/strong>NAV.IO issues an error alert to the administrator.<\/strong><\/p>\n \u279c Process assurance by INTRA<\/strong>NAV: If RTLS could not find the correct container ID from the system for the batch number (due to incorrect entry), INTRA<\/strong>NAV.IO issues an error alert to the administrator.<\/strong><\/p>\n <\/div>\n <\/li>\n \u25cf If the container with the release status is moved to the \u201ctransport zone\u201d, INTRA<\/strong>NAV.IO<\/strong> initiates an e-mail notification.<\/p>\n \u25cf The operator could use the report to check the position of the containers in the map with different filters (status, material number, container ID, batch number).<\/p>\n \u279c Process control by INTRA<\/strong>NAV: If the container with incorrect status (status not authorized, quantity does not correspond to the pre-set kg) remains in the transport zone for 2 minutes, INTRA<\/strong>NAV.IO <\/strong>initiates an alert e-mail notification, and the LED flashes red until the container is moved from the defined zones.<\/p>\n \u25cf The operator physically transfers the released container from the transfer zone in building A to the designated area in building B.<\/p>\n \u25cf Location and movements are tracked by INTRA<\/strong>NAV.IO<\/strong>.<\/p>\n \u279c<\/strong> Process reliability by INTRA<\/strong>NAV: <\/strong>If the hopper remains in the wrong zone for 2 minutes, INTRA<\/strong>NAV.IO <\/strong>triggers an alert e-mail and a flashing of the E-LED.<\/p>\n <\/div>\n <\/li>\n \u25cf The operator loads hopper powder into the dispenser with machine number and updates MES batch.<\/p>\n \u25cf INTRA<\/strong>NAV.IO <\/strong>updates the hopper E-Ink and the dispenser with the new batch (material number, batch number, batch barcode, quantity).<\/p>\n Manual operation: <\/strong>The operator initiates the update of the e-ink by pushing the function key to update the e-ink.<\/p>\n <\/div>\n <\/li>\n When the print job is finished, the operator posts the corresponding powder quantity by scanning in the MES or manually selects the E-Ink barcode via the MES powder consumption page.<\/p>\n \u25cf INTRA<\/strong>NAV.IO <\/strong>updates the batch information of the E-Ink every 30 seconds. Alternatively, this can be initiated manually via the function key on the e-ink.<\/p>\n \u25cf The dispenser is transported into the \u201cPowder room\u201d.<\/p>\n \u25cf The operator loads the remaining powder into the recycling container. The operator then creates a new batch of powder in the MES for recycling.<\/p>\n \u25cf INTRA<\/strong>NAV.IO <\/strong>updates the e-ink of the recycling powder (with status \u201cin use\u201d).<\/p>\n \u279c Process control by INTRA<\/strong>NAV: <\/strong>When the production hopper is moved in the recycling zone, the RTLS initiates blinking of the E-Ink for alerts. Reverse for recycling hopper.<\/p>\n <\/div>\n <\/li>\n \u25cf The recycle bin is moved to the \u201cTransfer Zone\u201d.<\/p>\n \u279c Process control by INTRANAV: INTRA<\/strong>NAV.IO<\/strong> initiates an e-mail notification if the hopper remains in the \u201ctransfer zone\u201d for 2 minutes. \u25cf Container with status \u201cRecycle\u201d is located in the \u201cStorage Zone\u201d in B-Building, INTRA<\/strong>NAV.IO <\/strong>tracks the location and movement history.<\/p>\n \u25cf Hoppers are moved to the mixing area, INTRA<\/strong>NAV.IO<\/strong> tracks location and movement history.<\/p>\n \u25cf After mixing, the recycled batch is updated and a new batch is created to match it in the MES (new batches with the status \u201cquality lock\u201d).<\/p>\n \u25cf INTRA<\/strong>NAV.IO<\/strong> updates the e-ink according to how it was defined in the previous steps.<\/p>\n <\/div>\n <\/li>\n \u25cf Operator moves the container with status \u201cQuality lock\u201d to the \u201cQuality zone\u201d.<\/p>\n \u25cf When the container stops in the \u201cquality zone\u201d, INTRA<\/strong>NAV.IO<\/strong> initiates an e-mail notification.<\/p>\n \u25cf Quality operator removes the sample from the hopper and carries out the powder test in the QMS.<\/p>\n <\/div>\n <\/li>\n \u25cf Quality manager releases the batch in the MES and INTRA<\/strong>NAV.IO<\/strong> will refresh the e-ink accordingly.<\/p>\n \u25cf The \u201creleased\u201d containers are moved to the interim storage, which initiates the notification for internal transport.<\/p>\n <\/div>\n <\/li>\n <\/ul>\n <\/div>\n <\/section>\n\n\n <\/p>\n\n\n\n Summary of the results achieved by our customer with INTRA<\/strong>NAV:<\/strong><\/p>\n\n\n\n \u25cf With real-time location tracking of powder containers via the Digital Twin RTLS platform, the energy company monitors the real-time status of all production steps. Downtimes, interruptions. Errors in the process flow can be identified immediately and eliminated more quickly. E-Ink TAGs can drastically reduce logistics and manufacturing processes. In combination with our INTRANAV.IO platform, customers can now send location-based information and instructions to the E-Ink display to automate and optimize processes on the shop floor or in the warehouse. Create workflows, rules and generate content depending on real-time information. \u00a0(The E-Ink TAGs are an INTRANAV.RTLS partner product).<\/p>\n Our INTRANAV software suite offers a broad portfolio of <\/p>\n\n\n\n
<\/p>\n\n\n![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/Header-3-17-5.png\")
\n\t\t\t<\/div>\n\t\t\t\n\t\t\t \n\t\t\t Process requirements of our customer <\/h2>\n\t\t\t \t\t\t
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1<\/h6>\n\t\t\t\t
Location and batch tracking of powder containers<\/h4>\n\t\t\t\t
2<\/h6>\n\t\t\t\t
Paperless factory: real-time status updates through E-Ink TAGs <\/h4>\n\t\t\t\t
3<\/h6>\n\t\t\t\t
Alert notifications in case of process deviations<\/h4>\n\t\t\t\t
4<\/h6>\n\t\t\t\t
Initiation of follow-up processes through geofence-based workflows <\/h4>\n\t\t\t\t
5<\/h6>\n\t\t\t\t
Workflow optimization through process and material flow analyses<\/h4>\n\t\t\t\t
6<\/h6>\n\t\t\t\t
Quality locking and authorization<\/h4>\n\t\t\t\t
IoT Requirements for INTRA<\/span>NAV<\/h2>\n
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![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/23-e1626961252721.png\")
\n Data transfer and interaction from cloud to local edge<\/h4>\n <\/li>\n
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\n Interaction between RTLS TAG and the E-Ink display <\/h4>\n <\/li>\n
![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/manufacturing-e1626961126947.jpg\")
\n Interface to the Mendix App and SAP<\/h4>\n <\/li>\n <\/ul>\n <\/div>\n <\/section>\n\n\n
INTRA<\/strong>NAV Real-Time Digital Twin:
Mapping the powder manufacturing process<\/h2>\n\n\n\n <\/h2>\n\n\n
![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/eInk-und-RTLS-Case-Overview-3-e1627392351634.png\")
\n\n\n<\/section>\n\n\nSolution from<\/strong> INTRA<\/strong>NAV<\/h2>\n\n\n\n
This is how the energy company uses INTRANAV<\/strong> in its
powder manufacturing process:<\/h3>\n\n\n <\/h2>\n
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![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/Header-3-18-2-e1627392696211.png\")
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<\/p>\nTransfer request<\/h4>\n
Transfer<\/h4>\n
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<\/strong><\/p>\n <\/div>\n <\/li>\n ![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/Header-3-23-e1627393456606.png\")
<\/p>\n![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/Header-3-17-2-e1627049037171.png\")
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<\/p>\nResults<\/strong><\/h2>\n\n\n\n
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\u25cf The interaction between RTLS and E-Ink Labels allows the transition to the digital factory (Paperless Factory), eliminating all manual data entry efforts and removing the need for manual updates. The batch\/status updates of the E-Ink are performed automatically by the real-time location of the container.
\u25cf Real-time notifications of the current production status, such as “too long dwell time in one zone”, “container is ready for pickup” or “the container is located in the quality zone” ensure that the entire production process is performed on time and in quality.
\u25cf Real-time alerts, e.g. if the containers have been transferred to the wrong zone or an indication of a manually required interaction, enable fast intervention in case of process deviations in order to avoid long waiting times of the production flow.
\u25cf Automated workflows initiate further follow-up processes, such as blocking safety zones (so-called quality blocking or release) or initiate pickup orders.
\u25cf Material flow and resource utilization analyses by INTRA<\/strong>LYTICS<\/a>, the INTRA<\/strong>NAV.APP “Flow Status”<\/strong><\/a> <\/strong>or the structured data export via CSV and the associated integration in analysis tools such as Power-BI, allow the determination of downtimes, idle and throughput times or zone occupancy periods as well as their utilization. For this purpose, INTRANAV records the exact time stamp (day \/ hour : minute : second) of the input and output of the respective zones and calculates, for example, the dwell time in the respective zone to the second. The final status indicates the total time of the transit of all zones and intermediate transit times per asset\/package\/material flow relationship. Based on the historical data of the completed transports as well as the dwell times of the containers at the passed zones, process optimizations of the production flow can be implemented.<\/p>\n\n\nINTRA<\/span>NAV.RTLS<\/span> E-Ink TAGs
for paperless logistics & production.<\/h2>\n <\/h4>\n
\npre-built E-Ink applications:<\/p>\n\n
![](\"https:\/\/intranav.com\/wp-content\/uploads\/2021\/07\/Social-Media-2-8.png\")
\n <\/div>\n <\/div>\n <\/section>\n\nTrue Values through the use of the INTRA<\/span>NAV SMART Production solution and E-Ink Labels.<\/h2>\n \n
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