Order Picking Systems

... deliver fast

Kommisionierung 1

Warehouse Station

Fränz & Jaeger builds solutions for paperbased and paperless order picking with pick by light or wireless terminals.

Stations for order picking (man-to-goods) are constructed in vendorspecific dimensions. They are arranged typically around a loop-conveyor.

Trays identified by barcode or RFID find their way to the stations. Optionally are control weighers at all stations. Therefore the system stores the empty weight as well as the current weight of each tray.

Trays are guided through the warehouse fully automaticliy by the DPS System. The system is fault tolerant and responds good-naturedly to manual intervention.

 

Ipunkt

I-Punkt

For paperbased order picking Fränz & Jaeger developed the "I-Punkt" with integrated printing. 

Press wholesale order picking

Many press-/book-wholesalers and publishing companies think about picking and delivering their goods in trays. Many successful field tests took place which proved that this approach showed more advantages than disadvantages:

  • There is high acceptance from their clients because the goods can always be delivered undamaged and without soil traces.
  • The slightly lower packing density of trays compared to stacks in the trucks has proven irrelevant in practice.
  • Trays are long-living and their costs are outweighted by the lower number of returned goods and the saving of strapping costs.
  • Order picking becomes much more smoothe and can be accomplished with higher degree of automation. This is the essential saving potential.

Order picking line

Wanne auf Rollband

Fränz & Jaeger GmbH, with their long year experience with press-/book-wholesalers, drafted a new order picking system based on trays:

Movement of trays by conveyor technology alongside the shelves.

  • Pick by Light
  • Automatic stop of conveyors if order picker is too slow
  • Automatic printing of delivery note at the end of order picking process directly into the trays
  • Weighing of trays on continuous scales and automatic push off to a control working place in case of weight dfferences
  • Continuous tracking of trays on clients' order

The facility is also suited for stack handling. This faciliates the phase of transition.

 

 

 

 

Sorter systems

... sorting at a good price

Sorter Aktion

The clients' situation

In almost any logistical use case goods must be sorted, here e.g. packages on truck tours. Although standard sorters provide a solution, they have benefits on top of what is most times needed and at a price that does not justify their operation. Alternatively, the only possibility was manual sorting.

Our solution

Sorter Simulation

We provide individually suited sorters laid out for an average capacity up to 3000 units per hour and a maximum weight of 40 kg. They can be composed using conventional conveyor technology and are priced accordingly. Fränz & Jaeger designs the best sorter system for your needs using approved components.

Control technology

DPS Sorter HV

Concerning the realization of control technology systems we use the latest technologies. Camera-based omnidirectional scanning and decentralized controlers based on WAGO IPC (Linux based with CeDeSys SPS component) to ensure our customers an optimal cost-effective solution.

Optimization

Simulation

Our special 3D simulation environment allows a faithful planning and simulation of the system in question with optimization of the controler in real time. The result is an efficient, cost-effective implementation without loss of production time.

Operational safety

ZMS

Even during operation, the system is continuously monitored by our process control system ZMS. It can be maintenanced locally or remotely at any time with new software versions over the network.

Conclusion

Fränz & Jaeger designs the optimal sorting system for customers needs composed of approved components:

  1. Identification and mapping - the applicated barcodes on the goods to be sorted are optically recorded from multiple sides by a camera system. For unambiguous identified units the sorter exit can be assigned fully automatically. Otherwise the recorded images are forwarded to a manual or teleworking editing place where they are identified by human workers.
  2. Weighing - Optionally the units can be weighted by a continuous electronic balance.
  3. Printing of result label - Finally an unambiguous result label is printed on lth fly. For this purpose we use printers with blowing air technology because they guarantee stable application even on rough surfaces.
  4. Sorter routing and ejection - The last step is to convey the unit to the actual sorter element which realizes the ejection (using pop-up or belt conveyer). The number of exits is only limited by the length of the facility.

Conveyer technique is realized in cooperation with notable vendors. The technique is operated and controled by our approved DPS-system (Decentral Programmable Controler). The successor of classic PLC (SPS in German) and ready for industry 4.0.

Material flow system DPS

... Industry 4.0 put into practice

PaketePlan

DPS is a flexible, integrating and cost-effective system of autonomous functional blocks.

The objective is to deliver of our customers an innovative, customized cost-optimized solution for the areas

  • material flow control
  • warehouse management
  • picking

which can be integrated with minimal effect on the production or logistics process even during operation.


The DPS System is not a monolithic application, but an open and integrating framework. Specific functional areas or intralogistic mechanics are mapped on the basis of a standardized communication and runtime environment with reusable modules.

These days, there are hundrets of modules for all conceivable tasks available E.g for different conveyors, pushing mechanics, barcode scan, label printing etc. 

Integration

It is the objective to support and integrate different mechanics, from diffenet vendors. Without generating a tight vendor lock-in.

Modernizations of existing hardware components can be done inexpensive and often during operation, or with little downtime.

We integrate goods-to-man and man-to-goods picking systems, eg. by means of a pick by light installation. 

Flexibility

F&J DPS modules, as well as manufacturer-integration modules can be replaced or supplemented by existing components or functionality of third parties if necessary. Only the core functionality of the communication and runtime environment is fixed.

DPS decentral programmable controller

Fränz & Jaeger uses the technology of decentralized, distributed and semi-autonomous control and application functions by software agents (software services). This corresponds to the current SOA technology (Service Oriented Architecture) within the IT.

Even a master computer is mapped via the software agent technology as a "logical" topology and is independent of its physical implementation (Host/IPC/PLC).

This allows running functions of material flow control and picking on a central computer, as well as autonomously on remote nodes.

Further, the topologies of the PLC, as well as that of the IPC's, or the PAC, is supported in parallel and also mixed in practice. We are using the CoDeSys IEC 61131 environments, STEP7, INFOTEAM IEC61131 or appropriate high-level languages C, Python, Java for business functions.

Optimal concept

The F&J concept decouples the application and control logic as well as business and process data from the actual process flow.
The business and process data of the material or assembly flow is transported in a kind of "docket" (Business data object) from control point to control point and from logic agent to logic agent in terms of the sequential control system. The electronic docket is evaluated and updated at any control point.

This concept makes it possible to map very complex processes and we can expand it while in operation.

It is also possible to integrate vendor specific "ready to use" funktionblocks to control agents, the material flow control remains independent.

 

Documentation systems

The clients' situation

Unpleasant, but well known: a customer claims to have not received an ordered amount or defective goods. Difficult to prove the opposite talking about complex products. Some examples from real life:

Example 1:  Magazine publisher X is direct supplier for bookstores at train stations. Customer Y complains to not have received a certain magazine. Was there an order picking fault,  i.e. an error at the supplier's site, or is the customer responsible? Basically that opens unfortunately the flood gates to cheating.

Example 2:  Legal obligation of product tracking: In some sectors, e.g. food industry, for some time it is required by law to keep records of the product life cycle allover from producer, supplier to the customer. But how to accomplish this in practice? The remedial measure is a documentation system.

Example foods

Dokumentationssystem

The F&J ESIBS-System:  Electronical System for Identification and Image Archiving of Beef Cattle.

The beef cattle is recorded with 4 cameras. Transponder ident, slaught ident and date of slaughter together with the cattle's automatic identified tattoo are registered in the system and saved redundantly. The data is added to the electronic documentation file and further processing steps are started. During ongoing operation it is possible to access documentation of the last three months without accessing any archive. Thus, questions about quality and state of the product can be clarified within seconds instead of hours formerly.

Example animal health state

In living animals health state is defined by the Body Condition Score (BSC). Manual determination of BSC is very time consuming and requires extensive personnel commitment. By means of  3D-Infrared-Cameras BSC can be determined automatically and thus costs get significantly reduced. The cameras scan the animal walking past, and the computed BSC is saved automatically together with the animal's ident in the documentation file. Thus quality and health of animals can be reviewed and documented continuously.

Example parcelled goods

A documentation system is a remedial measure here, too. In the named example photographs of incoming or outgoing goods are taken together with a standard scale. The barcode or address of the shipping order respectively are also scanned. These information together with the actual date are stored. The stored information can be recalled at any time via a GUI designed for search. Thus it is possible to prove if goods or packaging was missing or damaged.
State of the art PC systems are capable of handling the enormous amount of data and of storing images of several production months. Likewise today's camera and PC technology can provide such high clock rates in photography, which correspond to the usual speeds of conveying systems.

Maintenance with ReVis

ReVis optimizes your maintenance

Objects of all kinds require regular revision, for example, fire extinguishers, vehicles, industrial equipment, toilets, etc.

In addition to regular maintenance a spontaneous maintenance may be required, but then, who is responsible?

To date maintenance plans are hung-up to show who is when responsible. Tags eventually showed the next date.

With the aid of the new RFID ReVis label (ReVisTag) all these processes are accelerated and transparent.

The ReVisTag contains all the information that is required at the location of the object. The information is stored encrypted in ReVis Premium.

The ReVisTag "knows" when the next service is required, but also when the last had been done and who has done it.

Moreover, it also knows who is responsible for maintenance.

 ReVis App

The ReVis app

Using the ReVis app the ReVisTag is at first equiped with the required information, machine number and location, and the next maintenance date.

When you hold the smartphone just in the vicinity of the tag, it is read automatically and the display shows the next service date in the form of a clock. The maintenance personel can check within one second, when the next service would be required.

When maintenance has been carried out, the next maintenance date can be set easily. A new tag is not required.

The ReVisTag can be mounted on the object as legacy tags or even integrated. The standard ReVisTag is designed for metal surfaces.

But the ReVis app can do even more:

  •     Starting and ending a maintenance process.
  •     Start an email, SMS or a phone call for maintenance personnel.
  •     Leave a text message at ReVis server (see below)

The ReVis app is available for current Android devices with NFC option.

The ReVis server

The highlight of the ReVis system is the combination with our server.

All actions with the ReVisTag may (but don't have to!) be saved online to the ReVis server.

Each maintenance manager can retrieve the ReVis data and use it e.g. in form of an Excel spreadsheet.
Therefor data can be compared with maintenance plans.

The maintenance management is informed at all times, who, when, where, which ReVisTag has been read or has been changed.

The server is highly available worldwide (24/7) and secured. It is provided as a cloud application. A dedicated server is no longer needed.

The ReVis server service is very inexpensive and can be subscribed directly from the app.

Further informationen and ReVisTags are available exclusive from:

Fränz & Jaeger GmbH
Dornkaulstrasse 10
52134 Herzogenrath

Tel: +49 (0)2407 572705-0