Retrofit and modernization Restoring the reliability of technology
Operators of automated storage systems (high-bay warehouses, small parts warehouses, conveyor systems, etc.) are familiar with the fact that the PLC/mechanical system often "tweaks" in the same places over and over again. In most cases, you help yourself with daily symptom control. However, with the years of wear and tear, there is an increasing risk of frequent system failures . Targeted measures can help to restore the reliability of the system technology - but only if they are carried out in good time and with precision.
One of the daily challenges faced by warehouse managers is to ensure that their automated logistics system retains its value, availability and performance. However, after just a few years of use, the "ravages of time" begin to gnaw away at the installed technology and faults become more frequent:
- Spare parts have been discontinued or are barely available
(e.g. Simatic modules, Baumüller controllers, Interbus-S, Teubner keypads) - Older WMS/MFR systems are not compatible with current operating systems/databases etc. (e.g. Windows 7)
- Outdated bus systems
- Mechanical wear and tear
In addition, technical expertise is increasingly dwindling - especially with older systems. Qualified service and support can often only be carried out by individuals and protection is usually only possible with expensive service contracts.
The following results can be achieved through timely identified and targeted retrofit or modernization measures:
- Increased availability of your system (OEE), often by more than 20%
- Minimization of ongoing operating costs (spare parts, energy consumption, etc.)
- Performance and throughput increases of 10% to 30%
- High software stability
- Optimal remote maintenance options
In principle, it can be assumed that during the (then) implementation phase, components were used that were state of the art at the time, resulting in an availability of 98 % and more after the ramp-up was complete - for example, in automated small parts warehouses (AKL), high-bay warehouses (HRL) or shuttle systems.
It is precisely this reliability that is ultimately the indicator of maximum delivery capability and quality. However, continuous productive operation over several years (often in shift operation) leaves its mark on the technology, hardware and software. If the system becomes increasingly bogged down, there is a risk that goods will no longer reach their recipients on time or that the supply of the company's own production will no longer have the usual level of service. This may be tolerable in exceptional cases. However, if there are repeated delays, customer satisfaction decreases. A catalog of actions can be drawn up with comparatively simple means, with the help of which the reliability of the plant technology can be kept at a high level in the long term. There is no need for daily symptom-fighting and rising operating costs can be prevented. At the same time, a systematic retrofit with IGZ allows you to create the conditions for future "Industry 4.0" or "Logistics 4.0" requirements.
What are the main disruptive factors and causes?
Intralogistics solutions are often sophisticated structures that require smooth interaction between IT and mechanics, electrical and drive technology and the subordinate control systems (PLC). If even just one cog in the wheel jams, this can lead to a loss of performance.
After just a few years of use, the mechanical components of the warehouse and conveyor technology start to wear out. Once installed, bus systems become obsolete due to the ongoing technological leaps and (non-SAP) WMS/MFR applications are quickly no longer compatible with the latest operating systems and databases or the ERP system.
It also becomes critical if the original system supplier does not indicate in good time that replacement parts are about to be discontinued. It also becomes problematic when technological expertise at service and support level dwindles, for example due to the retirement of older experts or staff changes. Another aspect is that business models are changing. The associated requirements, which are not yet known in the planning phase, may no longer be covered by the existing system technology. The situation is further complicated by constantly increasing emission and safety regulations, including those prescribed by law.
How can disruptive factors in intralogistics be specifically identified?
Individually designed maintenance and servicing concepts - for example by IGZ Customer Service (ICS) - generally create the conditions for keeping the performance and efficiency of an intralogistics solution constantly at the required level. As part of this, it is advisable to document the work carried out cleanly and completely. In the best case scenario, a monitoring system is also implemented at an early stage of implementation that continuously monitors the processes and logs deviations from the target status. Ultimately, such long-term monitoring and evaluation can be used to generate reports that provide clear information about key fault parameters and their causes so that predictive maintenance measures can be initiated.
But even if the associated work (via remote maintenance or directly on site) has been carried out systematically and responsibly at the agreed intervals, one day the time will come when more in-depth interventions or modifications are required - for example in the form of a system retrofit . Those who have already taken appropriate precautions based on the preceding documentation and analyses outlined above are in a good position.
Where does the retrofit start and what benefits can be expected?
In addition to the necessary modernization services, retrofit measures also aim to increase overall equipment effectiveness (OEE) and reduce ongoing operating costs, for example in terms of energy consumption, spare parts procurement and maintenance. Provided the retrofit partner has the necessary experience and expertise, it is often possible to improve the flow of information at warehouse management and material flow control level. Furthermore, you can assume that the retrofit concept developed provides for a gradual conversion and expansion that largely excludes any disruption to ongoing productive operations.
The components that may need to be replaced include, for example
- Drives, motors and control technology
- Sensors, control technology and bus systems
- Material flow computers and warehouse management systems
- Mechanical equipment such as outdated storage and retrieval machines (SRMs) in automated small parts warehouses (AS/RS) or high-bay warehouses (HBW)
New mobile data collection devices (MDC), such as mobile terminals or wearables (now available in the form of smart gloves, vests, watches, etc.), can also increase performance and efficiency. It may also be advisable to expand the system infrastructure and implement new processes at the same time, particularly in the area of order picking(pick by voice, pick by vision, pick by robot, etc.). Such technological leaps make sense, for example, when new business processes need to be mapped that will help to future-proof your company in the long term.
No matter where to start – all retrofit measures always involve the much-cited "open-heart surgery". Against this background, proven technology and manufacturer-independent know-how and material flow expertise are essential.
Retrofit and modernization – Why with IGZ?
Systematically planned modernization of equipment and systems in the field of intralogistics also involves time and money. However, new investments can be avoided, resources can be planned accurately and experience has shown that the ROI (return on investment) is quickly amortized. The decisive factor here is the potential results that can be achieved:
- Increased availability of your system (OEE) - often by more than 20%
- Increased throughput rates of up to 30%
- Ensuring delivery quality at the highest level
- Improved stability and synchronization of the IT landscape with the help of SAP Extended Warehouse Management (SAP EWM) and SAP Material Flow System (SAP MFS)
- Complete SAP integration of existing and new processes
- Minimized interfaces and savings on third-party systems
- Reduction in ongoing operating costs (spare parts, energy consumption, maintenance/repairs)
- Development of efficient remote maintenance options
- Smooth entry into digitalization through SAP integration
- Tapping into further potential for the SAP-supported transition to "Industry 4.0" standards
Our offer for you
IGZ has the concentrated know-how from >300 successfully implemented retrofit projects and modernizations during ongoing operations.
The IGZ retrofit check for your plant technology:
- Inventory of PLC/control cabinet/sensor/actuator technology
- Assessment of effective retrofit measures and savings
- Assessment of safety and quality standards
- Potential analysis of SAP warehouse and material flow control
Sales SAP EWM General Contractor
