Real Time Location System RTLS
The RTLS (Real Time Location System) technology used in the analysis allows the identification and tracking of the location of objects (employees, components, transportation means such as logistics trains or forklifts, etc.) at a specific location (production hall, warehouse, etc.).
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Measurement data
The data from the performed measurements of the location of individual facilities over time subjected to optimization analysis by consultants and analysts, allows to make business decisions about the production/logistics/warehouse system on the basis of numbers, data and facts.
Measurement execution
The measurement is carried out for a specified period of time and covers selected facilities involved in the process under study. The end result is a report with analyzed data and recommendations, the implementation of which will allow to reduce waste and increase the stability of the studied process, and thus reduce costs and increase the efficiency of the process.
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The study allows for:
Measuring the utilization of human and infrastructural resources
With the real-time location system, we can measure an object’s activities and movement over time. We can also determine the efficiency of its use. This applies to both employees and transportation systems, and the study makes it possible to compare individual time periods (days/shifts) and designated zones and teams.
Mapping the production cycles
Measuring the turnaround time of selected operations of the production cycle and the flow of components using RTLS (Real Time Location System) technology allows the identification of waste and the subsequent implementation of process improvements, as well as serves to determine optimal indicators and norms.
Analyzing factors affecting production costs
Measuring the level of activity of individual facilities allows obtaining input data for activity-based costing.
Inference from created heat maps and spaghetti diagrams
Heat maps and spaghetti diagrams allow you to:
? analyze how objects move and how long they stay in a given place/zone,
? identification of non-standard behavior of the object (e.g., leaving the zone, too much time spent in the zone),
? the use of SMED (spaghetti diagram of the setter) or Autonomous Maintenance (inspection route) for the implementation of workshops.
Evaluation of the layout of the production area
With the use of real data, we can, for example, point out unused areas/surfaces or indicate the potential for changes in machine positioning (based on the distance traveled by the objects), which, combined with the experience of the consultants implementing the analysis, can translate into recommendations for changes in machine/equipment/ transport routes positioning.
Measurement of time spent in a zone and identification of bottlenecks
Measuring the dwell time of an object in a given zone makes it possible to make inferences about productivity, bottlenecks and real process flow.
Optimize the use of transportation resources
Monitoring the level of intralogistics infrastructure utilization allows:
? determining the optimal size of the fleet,
? minimizing unnecessary transportation,
? comparing between different zones, where transport means (specialized hand operated trucks, logistics trains, forklifts) are used.
Identifying areas for optimization projects
With the acquired data indicating problems with the production system, we can define optimization projects that will add value.
These may include projects concerning:
? optimization of the volume of work in progress,
? cost reductions,
? reduction of employee downtime,
? improvement of material flow.
Implemented improvements can also be measured to assess the effect of the applied changes.
Using a real-time location system (RTLS) and receiving the results from the measurements can also be helpful in implementing certain optimization measures. For example, when there is a project need to:
? optimize production flow according to Lead Time,
? carry out a thorough study of operator workloads, separating out individual process and transportation operations, in order to correctly establish work standards, cycle times and targets,
? monitor downtime, which is caused by input shortages (no operator, no materials delivered to the machine, no raw material) and output shortages (unclaimed products by the operator, forklifts),
? standardize cycle time,
? learn about the potential savings from a change in layout, or the implementation of supermarkets.