Predictive maintenance takes hold in today's increasingly connected distribution center, where sensors, software, and the Internet converge to improve system visibility and reduce downtime.
Victoria Kickham started her career as a newspaper reporter in the Boston area before moving into B2B journalism. She has covered manufacturing, distribution and supply chain issues for a variety of publications in the industrial and electronics sectors, and now writes about everything from forklift batteries to omnichannel business trends for DC Velocity.
Conveyor systems have long been embedded with sensors and connected to remote monitoring systems for maintenance and troubleshooting, but advancing technology is quickly taking things to the next level. Sophisticated sensing technology and Internet-enabled connectivity are delivering more detailed information to the DC floor, allowing organizations to move beyond routine preventive maintenance schedules and into the realm of predictive maintenance, where downtime is minimized, equipment availability is maximized, and productivity can reach new heights.
Conveyor equipment manufacturers and systems integrators are making this possible with solutions that emulate the "smart factory" movement, also known as Industry 4.0, in which automation, data exchange, and other technologies merge to create leaner, more productive manufacturing environments. In the DC, conveyor system solutions that incorporate the same technologies can provide greater visibility into mechanics and equipment usage, helping organizations avoid equipment failure and allowing them to take a more proactive approach to managing their conveyor systems.
"The enhanced ability to take action based on real-time information is what has transformed the performance of conveyor systems and automated material handling systems," says Ken Ruehrdanz, distribution systems market manager for systems integrator Dematic. "More sophisticated sensing technology, enhanced computing power, and the reduced cost of data gathering and storage allow systems integrators to track, identify, monitor, analyze, and optimize the performance of convey and sort systems."
And that translates to better all-around performance in the DC, adds Diane Blair, senior manager, international services and technical communications, for material handling solutions provider Honeywell Intelligrated. Blair emphasizes the pressure on today's DCs to work smarter and faster than ever before—while avoiding the lost revenue and the blow to customer satisfaction that comes from unplanned downtime.
"Everybody needs uptime, and they are trying to get as much availability out of the equipment they have—especially today," she says. "You never want a surprise when you're trying to ship a million boxes."
REAL-TIME CONNECTIVITY
The Industrial Internet of Things (IIoT) is driving much of the change occurring in conveyor system maintenance, particularly when it comes to monitoring the condition of equipment in the DC. Ruehrdanz points to advances in warehouse execution systems (WES)—software designed to control movement of products in a facility—as a case in point.
"In the era of the [IIoT], the WES can move from not only managing the operation [to] also optimizing conveyor system operation, repairs, and maintenance," he explains, pointing to Internet connectivity as the conduit for supplying more extensive, real-time data about the state of the conveyor system, down to the component level. "The maintenance management module of the WES software continuously assesses every portion of the conveyor network and then submits alerts when a threshold has been reached or a module is underperforming."
Those alerts allow technicians to schedule routine preventive maintenance—including automatic ordering of spare parts, in some cases. Analytics software records operational data, reporting trends and predicting future performance.
"Predictive analytics capabilities will continue to expand as IIot allows us to know what will happen, when it will happen, and what we can do about it," Ruehrdanz says. "This will allow warehouse and production operations to maximize operational excellence and strengthen the case for automation."
Similarly, predictive analytics are at the heart of Honeywell Intelligrated's Connected Distribution Center, a system that combines machine-level sensors, smart controllers, and connected devices for gathering data and delivering information on equipment health and facility performance in real time. Blair says the system allows unprecedented visibility into potential problems.
"It provides us with asset-level data that helps the customer set operations and performance limits," she explains. "We will see things we wouldn't normally see, such as a motor on a line way back in a system that makes a noise or vibration. [Technicians] may not see that until it gets to preventive maintenance—or they may not see it at all. It allows us to help them catch those anomalies prior to a failure, so they can address them before they become issues."
VIDEOS, APPS, AND MORE
High-tech connectivity is also helping to address labor-related concerns stemming from a dearth of technically trained conveyor maintenance technicians on the DC floor. Conveyor equipment makers and systems integrators are stepping up efforts to provide hands-on assistance with troubleshooting and maintenance needs by turning to IIoT-powered apps as well as emerging technologies such as virtual reality (VR). Mitch Smith, vice president of engineering for conveyor manufacturer Hytrol, points to the company's Hytrol Toolbox app that allows technicians to access equipment information and maintenance instructions on their mobile devices. The technician simply scans a serial number or 2-D (two-dimensional) bar code on the equipment in question to gain access to a host of information, including frequently asked questions and troubleshooting advice. The company provides video instruction in a similar way via its "Ask Hytrol" series on YouTube.
"One of the challenges the industry has—particularly material handling and a lot of e-commerce facilities and parcel facilities—is that there is a lack of trained and experienced conveyor maintenance technicians today," Smith says. "This leads us to integrate maintenance solutions by employing more controls, software, and other technologies."
Similarly, Dematic uses a smartphone app that allows technicians to stream live video or audio from an Android or iOs device. Called SiteView, the app enables Dematic's technical support team to see what the conveyor maintenance technician sees while hearing the technician describe the issue or ask a question.
Some companies are already using virtual reality tools for maintenance requirements, in the form of VR glasses and headsets that deliver hands-on instruction, for instance. Hytrol is developing its own Target Virtual Reality app that allows technicians to use their mobile device to hover over a piece of equipment, generating troubleshooting questions and step-by-step maintenance instructions on the device. Smith says the Target VR app will be released early in 2019.
"We're even looking at ways we can have online or video chat through this app," Smith says. "We're trying to connect the real world of what's going on in the field directly to the task at hand—and if need be, connecting to a human being at some point."
Smith adds that the race is on for conveyor solutions providers to bring more and more predictive maintenance capabilities to the table.
"It's about keeping the system running. It's about keeping equipment available for use," he explains. "At the end of the day, DCs are there to provide a service to consumers. It's our job to make sure the conveyor is running and available at all times. Being able to predict up front if there's a problem—that's what we're all trying to do."
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.