Case Study | Zero-defect solution for fire equipment suppliers

"The Kathrein RFID gates recognize the direction in which the containers are moving. So we know exactly which are empty and which are full. This rules out human error."

- Harald Dobesberger-Hofer, Kelllner&Kunz

Unwanted production breaks

Rosenbauer uses RFID-tagged KLT containers from RECA to supply the workers with the right C-parts at the production stage. To ensure seamless replenishment, these containers should be in a permanent cycle between the C-parts warehouse and the production line. However, the material flow at Rosenbauer was disrupted when empty containers were left at the workstation and not returned to the nearest collection box. The undesirable consequences: Too few or no parts were delivered to the assembly line and replenishment had to be triggered manually as a result. This cost time and money. A situation that the Rosenbauer management urgently wanted to remedy with a zero-defect solution.

From PoC to RFID solution for more process quality

The partners Kathrein and Kellner&Kunz had already focused on optimizing the processes through the extended use of RFID in the joint proof-of-concept, so that in the end an error-free, automated replenishment could be expected. As soon as the workers have used all the materials from the RFID KLT containers, they now pack the empty containers into a large transport collection box, the so-called I-Box. The tugger train driver transports all the containers in this I-Box and can collect more empty containers on his way. Boxes that the workers have inadvertently not placed in the I-box are now also taken into account. They can be recorded on the transport route in the same way as stacked containers. RFID eliminates the previous sources of error and ensures higher process quality.

From PoC to RFID solution for more process quality

Two locations now benefit from this Keller&Kunz replenishment system with a total of 15,000 bins. The Kathrein partner solved the challenge of the RFID reading processes in the drive-through area with two Kathrein antennas installed on both sides. When the tugger train driver drives through the RFID gate with the empty containers, an average of 200 containers at a speed of 10-20 km/h are reliably detected. The direction of travel is also detected. This is important in order to clearly distinguish between empty and full containers during transportation.

Integration costs reduced by Kathrein CrossTalk

Kathrein's CrossTalk software offers a huge advantage for both Rosenbauer and Kellner&Kunz: rapid integration of the RFID hardware into existing systems. Normally, data generated by RFID cannot be transferred 1:1 into other systems, e.g. the ERP. It must first be converted into standard formats. CrossTalk takes on this task quickly and cost-effectively with standardized pre-configurations for setting up the readers, the reading process, the conversion to other data formats and interfaces to other systems.

Conclusion 

The automated replenishment using Kathrein RFID antennas, readers and CrossTalk impresses Manuel Schwarzbauer, Head of Logistics Plant 1 at Rosenbauer: "Today, we no longer have unwanted production breaks because C-parts are missing. The containers deliver reliably, completely and just-in-time. The zero-defect solution has also given us reading accuracy on the 99%.

 

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Case Study | Zero-defect solution for fire equipment suppliers