Using SmartEYE™, we converted customers manual packing stations into SMART packing stations, virtually eliminating packing mistakes, as well as giving management REAL-TIME confirmation of shipping accuracy and shipping schedules.
Business Problem – Logistics company suffering product waste, additional shipping expenses and delays for their customers due to mispacked and/or late packages.
Solution – We instrumented the manual packing stations with barcode readers/scanners. We also added sensors to track packages with RFID tags and LED lamp to mark when a shipment is complete or incomplete.
Outcome – In a matter of weeks, Customer has SMART packing stations that: (a) alert the operators of any mispacked or missing items in REAL-TIME; and (b) give managers REAL-TIME confirmation of compliance with packing BOMs and production schedule. In Phase 2, all the data from the packing stations will be integrated into the customers in-house ERP system for seamless operational visibility on the production floor, real-time updates to inventory stock levels and building ideal profiles relating to operator efficiency (by kit-type, by shift and over time). Moreover, with 1,800 sensor options, SmartEYE™ can monitor, track, forecast and simulate almost any KPI desired.
In summary, the Customer is able to reduce waste (product and time), as well as virtually eliminate duplicative shipping expenses and customer delays due to mispacked boxes. The Customer is also able to confirm shipping schedule compliance in real-time. In addition, the Customer will have REAL-TIME updates to inventory, as well as the ability to monitor operator efficiency by kit-type, by shift and even over time.
Note: The Packing Station Market-Ready Kit is available for both manual packing stations, as well as conveyor-based packing stations.
With the SmartEYE™ Packing Station Market-Ready Kit, you can monitor items being packed and shipped, and/or items received and being placed into inventory, 24/7, and send all of the information to your network or directly to your ERP System. With the SmartEYE™ Packing Station Market-Ready Kit, there is no upfront cost (with subscription service), no interruption to production, and the system is installed and online in a matter of weeks.
The SmartEYE™ Packing Station Market-Ready Kit keeps track of all of the following in REAL-TIME …
- Product/Kit BOMs
- Items Packed/Unpacked
- Boxes Packed/Unpacked
- Total Time Taken to Pack/Unpack Each Box
- Packing Status
- Production Schedule Compliance
- Operator Performance (each kit, each shift, as well as over time)
Moreover, with 1,800 sensor options, SmartEYE™ can monitor, track, forecast and simulate almost any KPI desired.
The SmartEYE™ Packing Station Market-Ready Kit also sends REAL-TIME alerts to operators and managers of any deviations from the desired process including under-packed, over-packed or mis-packed boxes. The type, frequency and level of alerts can be customized based on customer preferences.
Because we offer Edge Computing, we can eliminate the need for the Cloud; provided, we also provide Cloud access via Microsoft Azure as an option for additional storage of historical records, more detailed data analytics, more focused hierarchal tracking and complete integration with other Cloud-based operations.
This small NEMA box houses SmartEYE™. Data from both wired and wireless sensors is aggregated to the SmartEYE™ “Edge Node” and processed locally on the Edge for real time analytics and machine models. Moreover, if the Cloud option is selected, this data is sent to the Cloud for analytics with a larger data set and integration with the company’s ERP/MRP system.
Hierarchical Management Dashboards show data at the station, line, cell, plant and enterprises levels. Data can also be viewed by the second, minute, hour, month, year or any other time frame desired. Management can start from the Power BI dashboard for an overview of operations, then drill down to the individual packing station dashboards, and further down to the individual kit data dashboards…all presenting real-time information. KPIs and analytics are done in real-time on the local dashboards showing alarms and situational data by individual station.
In fact, the data collected by SmartEYE™ is so fine-grained that process, resource, equipment and/or environmental deviations can be specifically targeted in real-time. Moreover, because SmartEYE™ can integrate the data from a customer’s entire enterprise, it allows the customer to compare the efficiency of different stations, resources and/or facilities. This integrated data also allows the user to run simulations to show the systemic effects of changes to schedules, resources and/or production processes before such changes are implemented.
Easy Installation (No Interruption to Production, No Changes to Equipment)
User-Friendly (Training takes less than 1 day)
Near-Instant Return on Investment
See How It all Works….
- 24 x 7 Real-Time Data Collection
- Station, Line, Cell, Plant and Enterprise Level Dashboards
- Production Quality Assurance
- Machine and Project Scheduling
- Machine Predictive Maintenance
- Installed and On-line in a Matter of Weeks
- No Changes to Equipment
- No Interruption to Production
- No IT Staff Required
- No Upfront Cost with Subscription Service
- Access to Microsoft Azure (as an option)
One Stop Shop: All elements required provided by Ectron Corporation including sensors, industrial-grade Edge computers with AI/ML capability, networking hubs, software stack, system installation and maintenance, data analytics.
Services Included in Standard Subscription:
- System Maintenance
- Standard Dashboards
- Customized Dashboards
- Track Additional KPIs (w/ over 1800+ sensor options)
- Data Analytics Consulting
- Business Intelligence/ERP System Integration
HOW WE STACK UP AGAINST THE COMPETITION: