CONDITION MONITORING

DO YOU HAVE YOUR

WAREHOUSE UNDER CONTROL?

FEWER MALFUNCTIONS AND BETTER BENEFITS

PROTECTION THANKS TO REMOTE MONITORING
Maximum availability
▪▪ Real-time analysis of error and
System availability makes or breaks the Our innovative SynQ software platform of- throughput trends
productivity of an automated warehouse. fers all the software components required ▪▪ Faster error detection/correction
Downtime caused by unscheduled system to achieve this. Business intelligence tools, ▪▪ Faster replacement of defective
shutdowns not only lower efficiency, they such as Swisslog Cockpit Manager, Availa- mechanical components
can result in delivery delays and an explosive bility Manager, Event Manager and, at the ▪▪ Condition Monitoring to perform system
rise in costs, which, in turn, affects customer core, our 3D real-time system visualization maintenance based on the current
satisfaction. Swisslog’s innovative Condition interface (SPOC), record the data generated condition
Monitoring solution is based on the idea of by the system. They give employees in the
detecting and correcting system component control center an intuitive and accurate Lower costs, reliable budget
changes caused by wear, excessive use and overview of all warehouse operations, ▪▪ Utilization of remaining service life of
other potential causes as early as possible – indicate where the failure of individual expensive equipment
ideally immediately after they arise. components would impact the entire flow ▪▪ Equipment operation with maximum
of goods, and are able to trigger proactive efficiency
SMART CONCEPT measures when needed. For example, if a ▪▪ Scheduled mechanical maintenance at
bin in the high-bay warehouse shifts or a budgeted costs
The core tasks of the Condition Monitoring palletizing robot runs too hot, the system ▪▪ Historical trend analysis for inventory
service include recording, analyzing and issues an alert before an incident arises. movements
visualizing information in order to provi-
de ongoing condition monitoring in the The Condition Monitoring plug-in adds an Calculated costs
warehouse, including all taks, processes and important feature to the functionality of ▪▪ Less downtime for critical equipment
warehouse components. State-of-the-art the SynQ software platform: It continually ▪▪ Ongoing system monitoring through an
sensors, data collection methods, and optimi- records the equipment condition by incor- early warning system for malfunctions
zation algorithms based on big data analytics porating the measurement and analysis of ▪▪ More reliable costs
are the cornerstones of our Industry 4.0 physical values, such as distances covered, ▪▪ Basis for implementing completely new
service portfolio that supports all Swisslog temperatures, energy consumption of indi- business and payment models (e.g. pay-
systems throughout their entire lifecycle. vidual elements and disciplines from state- per-use, pay-per-outcome)
of-the-art sensors into system reports. The

DESIGN ¦ DEVELOP ¦ DELIVER

collected infor-mation can then be used to COST SAVINGS THANKS TO necessary. This new approach to proactive
identify vital elements that are prone to mal- TARGETED MAINTENANCE maintenance and service offers enormous
functions and draw conclusions regarding cost-savings potential because the service
the potential error rates of individual disci- Swisslog Condition Monitoring allows you life of critical elements can be fully utilized.
plines and entire logistics systems. Condition to view the current condition of your system
Monitoring allows control center employees at any time. Our solution ensures that
to view the current system condition at any your system runs at maximum efficiency
time, docu-ment the development of trends across its entire lifecycle. Swisslog Condi-
and evaluate failure risks. The goal is to turn tion Monitoring replaces the preventive or
the data and data analyses into decisions reactive maintenance and service strategy
designed to improve the planning of opera- of the past. Instead of conducting routine
tions and maintenance processes to prevent checks at regular intervals and performing
system failures caused by malfunctions and scheduled replacement of intact parts with a
maintenance factors, especially those that specific remaining service life, maintenance
occur during peak periods and are therefore and spare parts provisioning occur precise-
particularly disruptive. ly when the data indicates they are really

CONDITION MONITORING POWERED BY

SYNQ: A UNIQUE COMBINATION

Condition Monitoring is a plug-in extension for the Cockpit Manager, an

add-on to SynQ. Ideally, you use both software modules as part of our
fully integrated SynQ warehouse management and material flow system
in order to benefit from the entire bandwidth of our growing number of
innovative business intelligence tools.

The Condition Monitoring solution uses the data collected by the hardware
components using state-of-the-art sensors. Whether it is the energy con-
sumption of a conveyor system, the deceleration path of a stacker crane,
the number of movements of a shuttle or the temperature generated by
the movements of a roller conveyor, our Condition Monitoring solution
provides continuous and seamless evaluations of the condition of all com-
ponents and disciplines in the warehouse.

Comparing the measurements and error events generated by the sensors

and stored in the data cloud against predefined target values allows devia-
tions to be diagnosed quickly and with pin-point accuracy. As a result, you
can determine 24/7 whether your system operates flawlessly or whether
there is imminent damage due to wear or excessive usage.

Event
Manager Storage
Utilization

Cockpit
Manager Order Labor / Task
Statistics Performace
Condition Monitoring
Cockpit
Intelligent
Part of our Intelligent Services, Condition Monitoring is a Manager
Services plug-in for our Cockpit Manager.
Print
Manager Condition Inventory
Monitoring Statistics

Availability
Manager Availability
Statistics

CONDITION MONITORING DESIGN ¦ DEVELOP ¦ DELIVER

COMBINABLE WITH EVENT interface. Information about the condition
MANAGER of the system can not only be displayed as
classic charts, but also directly on the system
Combined with the Event Manger SynQ add- visualization screen as, for example, heat
on, Condition Monitoring allows logistics maps which highlight all critical elements. A
managers in charge of warehouse opera- number of other apps from Swisslog can be
tions to initiate immediate error correction added to the chain of software modules. For
measures when a malfunction occurs. In example, the Report Manager can be used
addition, the system is able to address to generate a PDF report when a specific
problems on its own, such as issuing an problem is detected. This report, in turn, is
order to modify the storage and retrieval then e-mailed to the warehouse managers
strategy. You can predefine a number of by the Event Manager. The result is effective
different emergency scenarios and event reporting about all the errors that occur and
patterns in the Event Manager to avoid the corrective measures that are initiated in
losing precious time for error correction response.
when a malfunction does occur. In all cases,
Condition Monitoring offers interoperability 3D Real-time system visualization
with our 3D real-time system visualization

CONDITION MONITORING WORKFLOW

1
Collect
Data is collected down to the technical level and managed centrally by the system (energy consumption, temperature, x/y
movement).

2 Analyze
The Condition Monitoring system analyzes the data and processes it for decision-making and visualization.

3 Decide
Based on predefined rules or thresholds, the Condition Monitoring system decides which condition a device is in.

4 Intervene
Based on the system condition, the system knows which response is needed and initiates the corresponding action.

During data analysis, Swisslog differentiates between key performance indicators (KPIs) about throughput and error statistics which can be
measured without special sensors, and enhanced KPIs based on sensor values. The Condition Monitoring plug-in offers predefined dash-
boards and KPIs for both categories.

KPIS ABOUT THROUGHPUT AND ERROR KPIS ABOUT

STATISTICS MEASUREMENTS
▪▪ Average time to error correction ▪▪ Elements above the maximum temperature
▪▪ ▪Common errors (e.g. top 10 error statistics) ▪▪ ▪Error frames on field bus
▪▪ ▪Throughput of a specific warehouse component ▪▪ ▪Slewing distance covered by the crane
▪▪ ▪Downtime of a specific warehouse component ▪▪ ▪Total distance covered by all elements
▪▪ ▪Total number of system failures caused by malfunctions ▪▪ ▪Total driving time of all elements
▪▪ ▪Total number of error events by warehouse component ▪▪ ▪Energy consumption of all elements
▪▪ ▪Mean time between failures (MTBF) ▪▪ ▪Energy consumption of the warehouse
▪▪ ▪No-read rate of the scanner
▪▪ ▪Reasons for TU rejection
▪▪ ▪I-point performance report

DESIGN ¦ DEVELOP ¦ DELIVER CONDITION MONITORING

CONDITION MONITORING IS CLOUD-BASED
Since Condition Monitoring generates large amounts of data, Swisslog offers this innovative concept as a cloud-based solution. All data is sent
to the cloud using encrypted VPN tunnels. This cloud is private, i.e. only the owner and generator of the data has access. The latest IT security
techniques are used to prevent unauthorized access to this data. An integrated failover concept – mirroring of the data on a second backup
server – offers additional protection. Recovery mechanisms ensure that the data transferred to the cloud is never lost.

THE PATH TO INDUSTRY 4.0 BEGINS

WITH CONDITION MONITORING
Condition Monitoring is just the beginning of a future dominated by In-
dustry 4.0 technologies. It will allow Swisslog to provide maximum flexi-
bility and viability across the lifecycle of our logistics systems – whether
it is through modular system extensions, software updates or technology
innovations such as add-ons that leverage the latest findings of our data
scientists in order to optimize processes.

Building on Condition Monitoring, Predictive Maintenance Service will be

the next building block of our Industry 4.0 concept. Predictive maintenance
will be made possible by networking all automation sensors, integrating
external data into the complete system and detecting correlations and beha-
vior patterns. Our systems will send information not only about where a
problem will occur but also about when and how it can be fixed proactively.

ABOUT SWISSLOG
In today’s competitive world, companies As a full-service provider of automated Our order fulfillment and inventory solutions
must be able to deliver the right orders to intralogistics systems, Swisslog delivers enable companies to achieve the highest
the right customers at the right time. Errors everything companies need to optimize throughput at the lowest cost, efficiently
and delays in order fulfillment can have logistics from planning through handle large catalogs of SKUs, and accurately
lasting negative impacts on a brand while implementation. meet delivery demands and requirements.
maintaining high stock levels ties up capital
and reduces flexibility.

DESIGN DEVELOP DELIVER

CAD

Consult Analyze Plan Solution Choose Engineering Integration Installation Ramp Up Preventive 24/7-Support Optimization Moderni-
Solution Maintenance & Spare Parts zation &
Expansion

www.swisslog.com/monitoring