Case study. Implementation of the PdM RSIMS solution for a warehouse stacker crane

Project: Implementation of the PdM RSIMS solution for a warehouse stacker crane in a high storage warehouse at M-Logistic.

Implementation of the PdM for a warehouse stacker crane – challenge

The implementation of production plans is one of the basic goals that determine the efficiency of the production process. Unpredictable failures of the warehouse stacker crane caused a reduction in warehouse efficiency and generated unnecessary, unplanned direct and indirect costs connected with the need to repair this device.

Solution

M-Logistic decided to implement the PdM RSIMS from ReliaSol to precisely predict potential failures for the warehouse stacker crane No. 4, in the high storage warehouse at the plant in Tychy. The project was implemented by a joint team of specialists from ReliaSol and Maspex. It was conducted in accordance with the TBO methodology (THINK/BUILD/OPERATE).

The implemented and parameterized pilot predictive system (RSIMS) consists of a classic diagnostic system based on measurements of vibration acceleration and temperature, along with the anomaly detection system.  

The scope of the project included, among other things, delivery and commissioning of measuring equipment, preparation of sensor data for analytics, construction of models for detection of anomalies and their implementation on the PdM RSIMS (ReliaSol Intelligent Maintenance System) platform in the Cloud model. The implemented solution enables a remote analysis of the machine’s operation. Due to the lack of historical data, measurements (currently collected by the system) and conclusions from regularly conducted analyzes will be used in further steps to expand the system with prediction models for selected types of failures.

Benefits of implementing PdM for a warehouse stacker crane

During the first few months of operation, the system helped in the detection of two faults and enabled to detect anomalies in the operation of the system. Currently, thanks to regular data reviews, the system allows a deeper insight into the operation of the stacker crane and distinction of emergency anomalies from non-significant events. The implementation of the RSIMS predictive system has reduced the cost of failures and services. Currently, M-Logistic is able to determine the risk of failure in real-time and make effective and quick business decisions within the monitored stacker crane.

An additional effect of the project was the transfer of knowledge between ReliaSol and M-Logistic specialists. This contributed to an increase in the awareness of the company in the field of systems and machines.

• Faster detection of faults and (in the next step) anticipation of impending failures
• Constant monitoring and insight into the operation of the stacker crane
• Maintenance of a high degree of automation of the logistics process

Currently, M-Logistic is able to determine the risk of stacker crane’s failure in real time and make effective and quick business decisions. This led to an increase in the warehouse’s efficiency.

About M-Logistic

M-Logistic belongs to the Maspex Group – one of the largest companies in Central and Eastern Europe in the food sector. Maspex is the owner of the following brands, inter alia: Tymbark, Kubuś, Lubella, Łowicz, Krakus, Kotlin, Puchatek, Ekland, DecoMorreno, Cremona, La Festa and Plusssz (leaders in their categories). Their products are very trusted  among consumers. Maspex products are manufactured in 15 modern factories in Poland and abroad. Annually, the company produces 1.8 billion liters of juice, nectars and drinks, over 240 thousand tons of pasta, cereal and instant products, as well as almost 150 thousand tons of jams and preserves. The group has modern logistics and distribution centers, as well as high storage warehouses with 400 thousand pallet places. M-Logistic is one of the Group’s logistics centers. The company offers the highest level of services thanks to the complete automation of processes, and thus – the ability to prepare individual deliveries, excellent service, high standard and quality of service.