Flexible cell production
IPO.Plan, which entered flexCell, an algorithm for flexible cell production, was delighted to take first place in category 4. The planning experts at IPO.Plan present flexible cell production as a long overdue alternative to in-line assembly. At its heart is the flexCell algorithm, which the developers tested together with Boston Consulting Group (BCG) using real data from an OEM. By integrating the algorithm into the IPO.Log planning tool, flexible cell production can be simulated and the necessary automated guided vehicles (AGVs) can be controlled.

Calculations with real data show that assembly in flexible cells and the use of AGVs can increase worker utilization by twelve percent compared to the classic line. Labor costs are reduced by a similar percentage. An initial customer project has already been successfully completed. Another project is underway.

The planning experts from Ipo.Plan presented flexible cell production as an alternative to in-line assembly. At its heart is the FlexCell algorithm, which was tested with real data. © Ipo.plan

The special feature is that production does not take place in series, but in individual cells. Each cell is controlled individually. The FiFo principle is eliminated. The flexCell algorithm calculates the optimum occupancy of the cells and assigns the appropriate assembly orders to them. The material supply is then controlled using shopping baskets on AGVs. Cells that are not relevant for the product are simply skipped by the AGVs.

Matthias Kellermann and Tobias Herwig from Ipo.Plan accept the award from handling editor-in-chief Daniel Schilling. © WBM

The logistics are timed so that the product waits for the worker and not the worker for the product. As cells can be added or changed individually, the product range can be expanded as required and it is possible to react flexibly to volume fluctuations. The FlexCell algorithm simulates the changed occupancy of the cells at the touch of a button and triggers the redirection of the AGV to other cells. As only the respective cell is affected by adjustments or technical defects, a complete line standstill is a thing of the past. Companies with a wide range of products are the target group for flexible cell production.

Jury member Edgar Grundler congratulates Derek P. Clark and Manuel Granz from Losyco on winning second place. © WBM

Heavy load on rails
The second prize went to Losyco. The intralogistics specialist has developed a new type of steering platform for its LOXrail rail system for transporting heavy loads, which allows heavy, bulky assemblies to be turned and aligned directly on the conveyor rail. The new LOXrail all-rounder has specially designed, freely rotatable wheel sets with optimized rolling characteristics to make it easy to change the direction of travel.

This means that loads of up to five tons can be moved ergonomically by hand and redirected without the need for compressed air or electricity, as the load no longer needs to be lifted for a flexible change of direction. The steering system makes it easier to switch between longitudinal and transverse travel and saves time-consuming installation work for the installation of switches or turntables in the hall floor. Even with branching lines, no system components other than the LOXrail rail profiles and simple crossing elements need to be firmly anchored in the floor.

The Identplus 3D forklift guidance system enables scan-free and error-free intralogistics with forklifts. It is based on infrastructure-free forklift positioning on a digital warehouse map using a 2D LIDAR sensor based on natural contours of the current forklift environment. © Identpro

The forklift finder
The jury awarded third place to the Identplus 3D forklift guidance system from Identpro. It enables scan-free and error-free intralogistics with forklifts with a continuously synchronized material and data flow. Based on precise forklift positioning using natural environmental features, the forklifts identify picked-up load units such as pallets, mesh boxes, IBCs, paper rolls and the like exclusively via the x,y,z coordinates of the respective storage location, without any intervention by the driver. Forklift truck drivers are navigated to the requested pallets and warned directly if the wrong delivery positions are reached.

handling editor-in-chief Daniel Schilling, Roman Kucza from Identpro and jury member Edgar Grundler. © WBM

The basis of the forklift guidance system is the self-developed, infrastructure-free forklift positioning on a digital warehouse map using a 2D lidar sensor based on natural contours of the current forklift environment. The special feature here is the consideration of temporary and dynamic changes to contours in the environment, such as those caused by a truck. The repeatable accuracy indoors and outdoors is plus or minus ten centimetres. as

We also present the winners and products of category 4 in our picture gallery.