Eliminate the Bottleneck on the Truck Scale. Scott Dugan Command Alkon. Booth 2923
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1 Eliminate the Bottleneck on the Truck Scale Scott Dugan Command Alkon
2 Session Outline Before we automate, let s look at processes. Technology Overview Real World Examples Benefits, and Is it worth it? Project Implementation Approach
3 Site Process Overview What are the best practices? Every site is different slightly. Vehicle enters the site. Vehicle exits the site. Vehicle gets Loaded. Loading Area
4 Site Process Overview What are the best practices? This is what we d recommend. Know what product the vehicle is here to load. If not possible then find out. Exiting the site should be as fast as possible. Know exactly how much to load and load efficiently. Loading Area
5 Site Process Overview Check in Know which trucks are in your plant. Solve any issues up front (Credit, Expired Tare, etc.). Stage the ticket for more efficient loading and check out. Track Time in Plant for improvements. Know what product the vehicle is here to load. If not possible then find out. Loading Area
6 Site Process Overview Loading The better your targets, the better your actuals. Require a tare interval and don t depend on the driver. Store all weight exceptions electronically. Know exactly how much to load and load efficiently. Loading Area
7 Site Process Overview Ticketing Print the ticket. Eliminate this as a bottleneck. Get the vehicles off the scale and on the road. Exiting the site should be as fast as possible. Loading Area
8 Now that our processes are solid Let s take the next step
9 What are we trying to accomplish?
10 Other Benefits Customer Service Reduced Time In Plant Reduced Stress from Trucks Lined up Ticketing Accuracy After Hours Access Accommodate Spikes in Demand One Time Job? Safety Keep drivers in the truck
11 Technology Overview Let s Automate Know what product the vehicle is here to load. If not possible then find out. Exiting the site should be as fast as possible. Know exactly how much to load and load efficiently. Loading Area
12 Automate The Check In Process 1. Identify the Vehicle 2. Validate or Create Load Assignment 3. Direct the Vehicle Know what product the vehicle is here to load. If not possible then find out. Loading Area
13 Identify the Vehicle Hand Entered Handheld RFID Cards Truck Mounted Tags
14 Automate The Check In Process 1. Identify the Vehicle 2. Validate or Create Load Assignment Know what product the vehicle is here to load. If not possible then find out. Loading Area
15 Validate Load Assignment Pre-Assigned to a Load Vehicle Dispatch Manual Assignments by Weighmaster Repeat Last Load Dispatch Assignments
16 Create Load Assignment Create Load Assignment Driver selects from authorized choices Touch Screen Kiosk Kiosk
17 Validate or Create Load Assignment
18 Touch Screen Options
19 Touch Screen Options
20 Touch Screen Options
21 Touch Screen Options
22 Touch Screen Options
23 Touch Screen Options Raw Material Inbound Ticket #
24 Touch Screen Options
25 Touch Screen Options
26 Touch Screen Options
27 Touch Screen Options
28 Touch Screen Options
29 Touch Screen Options
30 Automate The Check In Process 1. Identify the Vehicle 2. Validate or Create Load Assignment 3. Direct the Vehicle Know what product the vehicle is here to load. If not possible then find out. Loading Area
31 Direct the Vehicle Traffic Lights Remote Outdoor Displays Touch Screen Kiosk
32 Traffic Lights Less confusion and faster processing of trucks Direct the Vehicle Gives simple indication of success/error at check-in and ticket out. Eliminate verbal communication and premature drive offs.
33 Direct the Vehicle Setup Examples Lane/silo indicators. Example: Check Vehicle in Plant Truck pulls on scale and views red light. Upon selection of load information a light is turned on indicating which lane or silo to proceed to for loading. Proceed C Lane/Silo C
34 Direct the Vehicle Remote Outdoor Display
35 Direct the Vehicle Touch screen Kiosk
36 Automate the Loading Process Know what product the vehicle is here to load. If not possible then find out. Know exactly how much to load and load efficiently. Loading Area
37 Automate the Loading Process Know exactly how much to load and load efficiently. Loading Area 1. Front End Loader Tools 2. Overhead Loadout
38 Front End Loader Tools Provides the loader operator with a real time display of trucks in plant. Eliminate lost trucks and product errors caused by verbal communication.
39 Front End Loader Tablet Load Station Checked In Vehicles Product to Load Qty to Load Time In Plant
40 Apex Loader Load Station Click to Load
41 Automate the Loading Process Know exactly how much to load and load efficiently. Loading Area 1. Front End Loader Tools 2. Overhead Loadout
42 Loadout PLC based loadout control with support for Silos over Scale, Negative Weigh, and Weighbatchers Load profiles by vehicle type Auto learn for consistent accuracy Driver initiated self-load option Integrate RFID to auto-populate Loadout operator screen
43 Driver Initiated Loadout RFID at Lane Entrance Strobe Light on Silo Pull cord to Initiate Drop Traffic Lights Direct Driver Through Process Light Generic Usage Definition Clear Idle Waiting for ID Input Yellow Input Accepted Accepted ID Flashing Yellow Action Pending Ready to Load Flashing Red In Action Loading (Gate Open) Green Success Load Complete Flashing Green Exit Exit Scale Red Error Errors
44 Attended or Self Load
45 Automate the Loading Process Know exactly how much to load and load efficiently. Loading Area 1. Front End Loader Tools 2. Overhead Loadout
46 Automating the Ticketing Process Know what product the vehicle is here to load. If not possible then find out. Exiting the site should be as fast as possible. Know exactly how much to load and load efficiently. Loading Area
47 Technology Overview - Ticketing Exiting the site should be as fast as possible. Loading Area 1. Identify the Vehicle 2. Remote Ticket Printing 3. Camera Integration
48 Identify the Vehicle Hand Entered Handheld RFID Cards Truck Mounted Tags
49 Technology Overview - Ticketing Exiting the site should be as fast as possible. Loading Area 1. Identify the Vehicle 2. Remote Ticket Printing
50 Remote Ticket Printing Easiest way to reduce time on scale Ideally 1 truck length away Driver stays in truck and out of scalehouse Can be used with automated or manual ticketing.
51 Remote Ticket Printing Unattended Ticketing Manual Ticketing
52 Where have we seen this before? Cameras We ll get to these. Order Pay Pickup
53 Technology Overview - Ticketing Exiting the site should be as fast as possible. Loading Area 1. Identify the Vehicle 2. Remote Ticket Printing 3. Camera Integration
54 Integrated with Ticketing
55 Combine Photo with Ticket Information Ticket number saved with image Easy retrieval by ticket number
56 What is a signature worth? Replace Signature Illegible Slow Maintenance
57 Combine Cameras with Scale Interface This is what we want... But, this is what we fear...
58 Scale Sensing Triggers No Ticket - Truck was on the scale and left but no ticket was generated. Tare Weight Contamination - Tare weight was above the threshold. Gross Ticket Mismatch - The max weight read from the scale was not within a reasonable difference from the actual ticket weight. Overweight - The weight read from the scale exceeds the vehicle s designated GVW. Scale Connection Lost/Restored - DVS cannot communicate with the scale indicator.
59 Technology Overview - Ticketing Exiting the site should be as fast as possible. Loading Area 1. Identify the Vehicle 2. Remote Ticket Printing 3. Camera Integration
60 Remote Ticketing Example Central Allocation and Ticketing Office
61 Lonely Scale House
62 Low Volume Location Example
63 Kiosk and Printer on Weighbridge Touch Screen Kiosk Printer Enclosure
64 Driver Interaction
65 High Volume Location Example
66 4 Inbound Scales
67 Minimal Personnel in Weighbridge Office
68 4 Outbound Scales
69 Benefits Customer Service Reduced Time In Plant Reduced Stress from Trucks Lined up Ticketing Accuracy After Hours Access Accommodate Spikes in Demand One Time Job? Safety Keep drivers in the truck
70 Let s Look at Some Numbers 1. Improve Time in Plant
71 Let s Look at Some Numbers 2. Improve Loading Accuracy
72 Time in Plant Improvements What are the benefits? 3
73 Analysis Let s define our parameters
74 Reduce Time In Plant What is this benefit worth? If we reduce in plant time by 3 minutes can we reduce trucking cost?
75 Time in Plant What is this benefit worth? 1.25 / minute Benefit per Day = 225 Benefit per Year = 56,250
76 Let s Look at Some Numbers 2. Improve Loading Accuracy
77 Loading Accuracy What are the benefits? 3.1
78 ROI Reduce Overloads What is this benefit worth? 3 If we reduce these 3 overloads can we save on Trucking Cost?
79 ROI Reduce Overloads What is this return worth? / minute Benefit per Day = 15 Benefit per Year = 3,750
80 ROI Improve Underloads What is this benefit worth?.1 If we can improve loading by 200 Pounds how much can we increase sales?
81 ROI Improve Underloads What is this benefit worth?.1 Benefit per Day = 143 Benefit per Year = 35,625
82 Get Help! Define Goals Project Planning Review / Define Complete Process As Is and To Be Capture Current Metrics Document Exceptions Sell the Plan (Early Buy-In) Go-Live Training Plan Users and Drivers Stabilize Capture New Metrics
83 Other Industries Nebraska Furniture Mart Redbox Fast Food Loader
84 Summary One solution does not fit all locations. RFID and Remote Printing are biggest bang for the buck low hanging fruit. Truck drivers can use these systems. Get help. This is done all over the country world. Not just for high volume locations. Keep it simple.
85 Thank You for your Time. Questions?
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