Content from our sponsor

Major Aerospace & Defense Company Taps IoT Sensor Solutions to Boost Productivity

BAE Systems improves efficiencies with Enterprise Sensor Integration (ESI) from Tapestry Solutions

<p>Pictured are BAE Systems’ team members during production.</p>

Pictured are BAE Systems’ team members during production.

Technology in the News

Making the Case for Using a Transportation Management System for Parcel Shipping
XPO cites steady adoption of Drive XPO carrier app
Kenco Logistics plans to open up dedicated physical warehouse space focused on innovation
Driving 20% More Revenue with APIs
BlueGrace Logistics Founder and CEO Bobby Harris offers up state of markets
More Technology News

Technology Resource

Making the Case for Using a Transportation Management System for Parcel Shipping
We discuss the key pain points that all parcel shippers are dealing with right now and show how a multi-carrier transportation management system can help reduce costs, improve efficiencies, and improve the organizational bottom line.
All Resources
By ·

Smart factories are fast becoming a reality as manufacturers leverage Internet of Things (IoT) sensor technologies to connect people, data and processes across their factories and supply chains.

This case study examines how BAE Systems achieved IoT connectivity – significantly boosting productivity, asset visibility and supply chain management – with the help of Enterprise Sensor Integration (ESI) from Tapestry Solutions, a Boeing Company.

Overview

BAE Systems, an international defense, aerospace and security company, had an immediate need to find new technologies and techniques to accelerate manufacturing production processes in response to increased customer demands.

The primary task was to replace existing manual processes with an automated, Radio Frequency Identification (RFID) solution to efficiently track and manage inventory, assets/tools and workflow processes. This would support the company’s overall goals of enhancing factory tracking and awareness capabilities; supporting ramped-up production efforts; and reducing non-value-added activities.

The company hoped to attain a near-real-time view into its assets and processes, and integrate that data with its existing sensor technologies and Enterprise Resource Planning (ERP) systems. It also wanted the solution to have sufficient flexibility and scalability to grow with technology advancements and its evolving enterprise needs.

The Challenge

Previously, the company had a largely manual process for tracking and managing inventory, asset and tools, as well as enhancing workflow on the assembly floor.  It used a manual barcode scanning process to track and replenish inventory at multiple sites. Procurement teams then released orders manually, which often resulted in longer than desired lead times.

To achieve lean manufacturing goals and reduce costs, BAE Systems sought a solution where materials could be replenished using “pull” methodology – based on just-in-time demand – rather than a “push” system where materials are stocked based on forecasted demand. 

Without automation, the company lacked asset visibility and accountability. As an added complication, particular tools had to be manually monitored for calibration to meet compliance and regulatory requirements.

The Approach

Tapestry Solutions set out to provide an Internet of Things (IoT) solution for BAE Systems, leveraging RFID as well as Enterprise Sensor Integration (ESI) technology that it implemented across 50 factories for Boeing, its parent company.

ESI is a software solution that connects myriad sensors and data sources onto a common platform.  As a sensor-agnostic solution, ESI can be integrated with an organization's legacy RFID and sensor systems – regardless of hardware or sensor type.  It integrates sensor data with customer enterprise systems, such as ERPs, to drive operational automation and efficiencies.  ESI can operate in the cloud or on dedicated, on-premise servers.

ESI technology saved Boeing $100 million during its first year alone – largely due to reductions in assembly time, automated asset receipt and payment, enhanced inventory management, and improved quality and safety.

Tapestry commenced work at BAE Systems in July 2017, and then installed the hardware in two phases during the fall of 2017. By 2018, the solution was successfully implemented at BAE Systems’ Electronic Warfare Integrated Manufacturing Center (EW-IMC) in Nashua, New Hampshire, followed by several other sites.   

The installation supported the following business use cases:  automated material replenishment, asset and calibratable tool tracking, and Work-in-Process (WIP) tracking.

The Results

BAE Systems reports that the ESI-enabled RFID solution has significantly increased production capability at its factories and through its supply chain, thereby improving current and future production programs for its customers. The technology provides BAE Systems with the capability to track 200,000+ assets, 30,000 parts, and an estimated 6,500 work orders at its facilities.

The company is beginning to eliminate manual barcode scanning processes in many areas. This has enabled BAE Systems to transform from a “push” scheduling process to a “pull,” where there is a just-in-time inventory flow through its supply chain.  

Material Management

To track and replenish materials via RFID, BAE Systems selected a TwinBin RFID Kanban system with specialized material-storage containers. The system is used in conjunction with customized mechanical RFID flags, which send signals to suppliers once the stock level has been depleted to the determined re-order level.

That data is collected every day via BAE Systems’ centralized database. Orders are automatically generated every night, and the parts arrive at a pre-determined time at the Material Center. The ESI software provides web-based reports for the location of material-storage containers, bins and shelving systems.

Today, BAE Systems has more than 9,000 unique parts numbers that are actively available for auto-replenishment directly to its suppliers.

Tools and Asset Management

For asset and tool tracking, BAE Systems has applied UHF RFID tags to tools used during the assembly process. A combination of RFID readers are installed at portals or chokepoint areas to capture data from the RFID tags as they pass.

The system can also track which items enter specific zones and which ones return from those locations, thereby helping users to identify any misplaced tools or materials.

The software enables workers to create parameters indicating which zones specific tools or assets can enter and leave. They then receive alerts via , XML, or SMS messages if there is a change in status or an unauthorized event occurs.  

ESI has improved operational visibility through its mapping applications, visually displaying asset locations on maps and building layouts – based on a part or tag number entered in the system – providing decision-makers with total asset visibility.  ESI can also monitor recalibration due dates on equipment and can send associated alerts to management.

For WIP, RFID tags are applied to printed work orders as they are initiated, which enables tracking of each open order as it moves through the production floor. The work order then follows the movement of each product as it proceeds through the assembly process, allowing the company to keep track of the order’s status and identify possible bottlenecks.

Future Enhancements

The next steps for BAE Systems include launching portal readers at engineering labs this year, as well as selecting installation sites for 2019 and 2020. Future enhancements will include supporting chemicals management — automating the tracking of perishable materials and providing expiration alerts — as well as electrostatic sensitive device (ESD) audit validation.


Subscribe to Logistics Management Magazine!

Subscribe today. It's FREE!
Get timely insider information that you can use to better manage your entire logistics operation.


Article Topics

Boeing · ERP · RFID · Tapestry Solutions · All Topics
Latest Whitepaper
Making the Case for Using a Transportation Management System for Parcel Shipping
We discuss the key pain points that all parcel shippers are dealing with right now and show how a multi-carrier transportation management system can help reduce costs, improve efficiencies, and improve the organizational bottom line.
Download Today!
From the June 2019 Logistics Management Magazine
Over the years, we’ve tried to steer clear of too many themed issues because we’re proud to offer our readers a wide breadth of industry information. The logistics and transportation market is so diverse, and shippers are looking to solve a multitude of challenges across a number of modes and services areas—never just one.

Warehouse Execution Systems (WES) Evolves Beyond “inside the four walls”
Got labor? How supply chain companies are recruiting talent during a labor crunch
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly newsletter!
Latest Webcast
How to Solve The Unique Challenges of Multi-Carrier Parcel Shipping
Join Logistyx President Ken Fleming for an appraisal of multicarrier shipping, TMS solutions and the nuances of interpreting Gartner’s Magic Quadrant for TMS, without a barcode label in sight! Using case studies, review scenarios traditional TMS solutions struggle to manage, such as high volume and international shipping, and learn why parcel shipping requires a different solution and how to design your process and architecture to leverage both effectively.
Register Today!
EDITORS' PICKS
Got labor? How supply chain companies are recruiting talent during a labor crunch
How are companies faring in the race to recruit and train high-level supply chain talent in a market...
35th Annual Salary Survey: Compensation matters more than ever
While job satisfaction remains the primary reason for today’s logistics managers to stay with one...

2019 Rate Outlook: Pressure Builds
In 2019, the world economy will enter a third straight year of broad-based growth, but many...
2019 Transportation Management Systems (TMS) Market Update: Keeping pace with the times
The transportation management systems market is growing right along with the number of challenges...
www.zaraz.org.ua

частный кредит под залог недвижимости

velomarket.org.ua