Schad, developer of the EXTEND7000 mobile SCADA system has implemented a mobile solution for BAUR Versand, one of Germany’s oldest multichannel retailers. BAUR is using EXTEND7000, a mobile SCADA system that allows the monitoring and control of automated processes to be extended to an ordinary mobile device, smartphone or tablet, in its logistics departments
BAUR operates three large, fully automated logistics departments at three locations in Germany, responsible for controlling warehouse receiving docks, high-rack storage machinery, conveyor belts and sorting technology. At these sites, BAUR operates a variety of different conveyor systems and 14 stacker cranes (SRMs), controlled by over 60 programmable logic controllers (PLCs), which are monitored around the clock from the company’s central control room’s WinCC visualisation system.
In 2011, BAUR implemented Schad’s mobile SCADA system, EXTEND7000, which has resulted in employee efficiency increasing by 15 per cent and the company’s support telephone call costs reduced by 60 per cent.
“Business trends are clearly moving towards enterprise mobility, it is unstoppable. In two years everyone will have a smartphone so it is only natural to utilise them to improve business processes,” says Roland Säum, BAUR technical services project manager. “To ensure the most efficient workflows, employees should be able to receive logistics technology notifications and have access to system controls anywhere at any time. EXTEND7000 helps us by avoiding unnecessary walkways, improving the efficiency of staff deployment and saving time – thus increasing productivity.”
Complex logistics demands
BAUR’s automated warehouse is a highly complex environment. In total, there are around 70,000 defined notifications within its logistics technology including conveyor states such as ‘running’, ‘standstill’, ‘maintenance switch off/on’ or run time errors. All notifications are sent to the central visualisation system in the control room, which is staffed by several employees around the clock. On average, these employees forward around 60 cases each hour to the relevant technicians.
“The use of mobile technology simplifies and optimises communications and efficiency of operations,” adds Säum. “EXTEND7000 offers an affordable and functionally rich solution for mobile monitoring and control of all our logistics technology.”
Before integrating EXTEND7000, control room technicians would individually call maintenance engineers and verbally forward on error messages. However this caused workflow issues because control room personnel were not aware of which of the 35 engineers were in service, or, whether they had already accepted previous tasks. As a consequence, several calls were required in order to locate an engineer able to take over the given task – resulting in an unnecessary loss of time.
EXTEND7000 was directly integrated into the existing system control concept and coupled with the WinCC visualisation system. Now, incoming notifications are simply sent directly from here to the technician’s BlackBerry devices. In this way, technical staff can receive alerts at anytime, regardless of their location.
Reducing support call costs
Before introducing EXTEND7000, each employee carried normal mobile phones with call tariffs. Today, smartphones are being used with more cost effective ‘call and data’ tariffs. Since call times have now been reduced by 60 per cent, the additional costs incurred by contract conversion were immediately covered. Additionally, EXTEND7000 also serves as a backup if the central WinCC visualisation fails.
As part of phase 1, EXTEND7000 has been used to pass on an initial 3,000 to 4,000 maintenance error notifications. However, BAUR’s long-term goal is to communicate a greater level of information and notifications through Schad’s mobile SCADA software. In the future, EXTEND7000 will be used to inform middle management, for example about plant states, number of units, individual departments’ work progress.
