Optimization of intralogistics
TKMS GmbH is a leading shipbuilding company specializing in the production of ultra-modern submarines. By using INDUTRAX software with real-time positioning, the company was able to significantly improve its transportation processes and worker guidance for forklift truck drivers last year.
The motivation
Precise and reliable intralogistics are crucial at the shipyard site in Kiel: every day, components, semi-finished products and parts in up to 200 load carriers are moved by industrial trucks between 67 different buildings and halls on the 31-hectare site.
Transport processing requires precise coordination in order to provide the required parts on time and in the right place so that production can continue without interruption.
The material flow is organized in SAP EWM, triggered by material requests from production. Until now, however, the control and execution of movements was based on paper printouts and manual feedback from employees in SAP EWM.
In 2023, around 40,000 transports were carried out in this way. Incorrect or missing records led to a lack of transparency and documentation gaps, which in some cases caused considerable search effort for employees and, in the worst case, interrupted value-adding activities in production.
23
Locations worldwide
8.500
Employees
31 ha
Site (Kiel)
185
Years of expertise in shipbuilding
< 200
Daily transportation
67
Production building Kiel site
40.000
Transports per year
The solution
By integrating the INDUTRAX ASSETTRACKER application into the existing system landscape and using the TransportAPP on the forklift terminals, TKMS was able to implement a fully digital solution for transport processing and worker management. The result? Fewer interruptions, more transparency regarding material flows and a sustainable increase in overall efficiency.
Using a combination of state-of-the-art tracking technologies from GPS, Quuppa RTLS and BLE presence detection, complemented by seamless integration of SAP EWM, this solution ensures:
- Fully automated bookings in SAP EWM: The documentation effort for employees on the industrial trucks is reduced to a minimum. Without paper and manual intervention, the transport process runs more efficiently, while they only need to intervene in the event of conflicts.
- Significant reduction in error rates: Incorrect bookings and incorrect unloading are significantly minimized. The improved reliability of item information in SAP EWM increases transparency and enables more effective planning and control of the material flow.
The project objective
In order to consistently leverage efficiency potential, TKMS opted for a forward-looking approach: a solution with tracking technologies for the automatic tracking and documentation of transport orders. Targeted worker guidance should not only digitize the control of intralogistics and minimize the search effort, but also gain back valuable time.
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The solution design
The introduction of digital worker guidance and automation of transport tracking is based on the INDUTRAX application ASSETTRACKER and the mobile app TransportAPP in conjunction with SAP S/4 HANA EWM.
The following technologies and systems were integrated:
GPS-enabled tablets
Worker guidance via TransportAPP
Transport orders to be processed from SAP EWM are displayed on GPS-enabled tablets mounted in industrial trucks in list and map views in the INDUTRAX TransportAPP user interfaces. Real-time information on position and processing status enables employees to act quickly and purposefully, avoid incorrect unloading and automatically record feedback.
RTLS Tags
The transported goods are equipped with RTLS tags to enable automatic location tracking
Quuppa-compatible BLE tags from the manufacturer Tatwah are used to transport orders. These ensure end-to-end transparency and simultaneously guarantee the plausibility of the transports to be carried out, especially on arrival at the unloading points on the shipyard site.
RTLS infrastructure
Location tracking with Quuppa RTLS inside the building and outside unloading points
The relevant areas of the unloading points are equipped with a network of Quuppa RTLS locators, which enable automatic position detection of the BLE tags. Outside the unloading points, the location tracking of the industrial trucks is realized using GPS. Thanks to the seamless integration of both tracking technologies into the INDUTRAX software, continuous tracking is ensured and the automation of work processes is further optimized.
SAP S/4 HANA eWM
In exchange with Extended Warehouse Management (SAP EWM), employees have direct access to the transport order data, such as pick-up location, destination, order prioritization and the distance to the pick-up location based on their own position. Actions are triggered via a simple button press in the software. Material movements recorded by the RTLS are used to automatically trigger bookings in SAP. Paperless processing promotes optimized process documentation, minimizes sources of error and enables improved decision-making in the operational area.
Result and outlook
With the introduction of the INDUTRAX ASSETTRACKER and the TransportAPP, TKMS achieved the following results:
- Reduction of manual scans through automated postings in SAP EWM
- Increased transparency of the material flow and the positions of the load carriers
- Significant reduction in search times and incorrect bookings
- Optimized use of resources through digital worker guidance
- Increasing overall efficiency in both logistics and production
Your contact person
Experience the benefits of digitalization in logistics and production! With our tailor-made solutions, such as ASSETTRACKER and the mobile app TransportAPP, you can reduce errors, optimize processes and relieve your employees with efficient digital tools.Dr. Andreas Schürzinger
Principal Consultant IoT
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Interested? Get in touch with us now and discover how we can take your processes to the next level together!
