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IFOY Test Report: Computed MyoGraphy by Predimo

Posted on by Keith McKinley

The latest submission in the IFOY Award finalists to come under the microscope ahead of the announcement ceremony later this week is Computed MyoGraphy by Predimo.

Computed MyoGraphy is a tool for evaluating workplaces in terms of ergonomics and process efficiency. The unique technology is based on a digital human twin that allows you to look inside the human body and recognise what each individual muscle is doing. For the first time, it is thus possible to indicate overload as a key figure. The resulting advice reduces sick days and thus helps to counteract the shortage of skilled workers.

IFOY category: Start-up of the Year

IFOY Test Report

Computed MyoGraphy is composed of a hardware part and a software part. The hardware part consists of 17 IoT sensors that are worn over the work clothes with Velcro straps. These sensors are needed to record the movement of the worker. Based on the data thus obtained, a cloud application calculates the activity of each muscle and the load on the joints. In the visualisation software, these loads can be analysed to derive ergonomic recommendations. In combination with fully automated process and material flow tools or simple productivity verifications, precise key figures for ergonomics and productivity can thus be defined.

Due to the amount of data, ergonomics can also be correlated with productivity for the first time and it is shown that ergonomic workplaces automatically lead to personnel working faster. In intralogistics, the application is particularly useful in picking or packing areas.

Previous ergonomics analyses are based on a view of the human body and cannot look inside the body. This means that they cannot describe the overload as a key figure, but only approximately. With the help of certain joint angles, an attempt is made to describe this key figure: for example, working above shoulder height is bad, an inclination of the upper body of more than 30° is unergonomic. However, according to the current state of science, it is known that these currently common findings do not correspond to the real load. It often happened that previous ergonomic workplace optimisations did not lead to a reduction in lost workdays, but rather increased process efficiency or reduced picking errors, for example.

With Computed MyoGraphy, it is possible to define overload as a key figure that has a direct influence on lost work days, thus enabling a “real” ergonomic analysis. In the area of process analysis, state-of-the-art tools are used that can be used without integration into the IT structure. This gives Predimo a unique selling point in the field of health/ergonomics that is unparalleled anywhere else in the world.

IFOY test verdict: Computed MyoGraphy is a tool for evaluating workplaces in terms of ergonomics and process efficiency. The technology is based on a digital human twin that allows you to look inside the human body and see what each individual muscle is doing. This makes it possible for the first time to indicate overload as a key figure. With Computed MyoGraphy, fixed values and full transparency are available from which measures can be derived that really help and with which an ROI can be determined. Mainly in combination with process analysis, this results in insights that increase health, well-being, and productivity. The resulting recommendations reduce sick days and thus counteract the shortage of skilled workers. Health insurance companies are required to provide financial support for the analysis. The amount of support depends on the number of insured employees of the respective health insurance company and other factors in the company.

IFOY Innovation Check

Market relevance: In the foreground of the market relevance estimated by Predimo itself is the constantly increasing shortage of skilled workers. This is to be counteracted, especially in the field of logistics, with the help of the product Computed MyoGraphy. This is realised by a recording of the motion sequence of the employees, which is used as input data in a complete digital twin of the human motion (muscle) and skeletal (bone) apparatus for an evaluation of the body loads. By optimising processes regarding to less body-straining procedures, the health of the workforce is sustainably promoted. Sickness and absenteeism can thus be reduced.

Customer benefit: Both for the companies and their employees, the process flow can be optimised, occupational health and safety is effectively supported and, at the same time, an increase in performance is usually achieved. An analysis of the individual body loads is here the basis for an evaluation of the current processes. This analysis is carried out by Predimo as a service provider and offers the very great advantage that detailed results are obtained for the areas of health, occupational safety, process design and performance evaluation, which can reveal valuable optimisation potential for both the employee and the company.

Novelty / Innovation: The innovative leap consists, on the one hand, in the construction of an extensively complete digital twin of the human bone and muscle apparatus, which, in conjunction with adapted simple measurement sensors, permits a comprehensive and detailed load analysis of the human body. The data required for this is obtained via the sensors directly during the process and then analysed. The unique selling point here is that the analysis is virtually placed inside the body and the effects on the musculoskeletal system are examined directly.

Functionality / Type of implementation: For the measurement, only a few sensors need to be installed on the test person and these are little disruptive during the workflow. Then the digital twin with the test data is activated via a software tool. The analysis of the results requires solid expertise and is carried out here by Predimo as a service provider.

Verdict: Predimo’s Computed MyoGraphy is primarily a newly constructed digital twin of the human bone and muscle apparatus. This, in turn, is linked to movement data recorded by acceleration sensors from the person to be analysed in the course of his or her operational activities. The result – manually evaluated by experts – is a load profile of the employee’s musculoskeletal system. Furthermore, the risk potential is analysed, a structured process analysis of the activity is carried out, and a performance evaluation is performed.

Market relevance Ø
Customer benefit ++
Novelty / Innovation ++
Functionality / Type of implementation +
[KEY: ++ very good / + good / Ø balanced / – less / — not present]

IFOY Test Report: NIMMSTA Light Tag

Posted on by Keith McKinley

As we enter the week when the IFOY Awards are handed out in Dortmund (on Thursday June 22nd), we continue our look at all of the 2023 finalists and share the verdict from the IFOY test conducted during the evaluation by an expert jury in March. Our next entry is the Light Tag pick-by-light solution from NIMMSTA GmbH.

The NIMMSTA Light Tags represent a completely new approach to a pick-by-light solution that achieves up to 80% more efficiency without integration effort and in combination with the NIMMSTA Industrial Smart Watch.

IFOY category: Special of the Year

IFOY Test Report

NIMMSTA had set up a shelf at its booth where visitors to IFOY TEST DAYS could try their hand as a picker. So what could be more natural than putting on one of the company’s hand straps and getting started? The task for visitors was to pick five products. Without assistance from NIMMSTA’s system, it took the tester 112 seconds. But it can be even better. With support from the Light Tags, the time could be reduced to 74 seconds.

The approach to the solution is completely new, because the “Light Tags” contain only battery-powered LEDs (battery life: three to five years) that light up in different colours and patterns. All the logic is in the NIMMSTA wearable, which personnel wear directly on their bodies. This combination makes all intralogistics processes digital and more efficient.

Via Bluetooth, a position is assigned once to each light tag in the NIMMSTA app. The light tag is then attached to the corresponding storage location with an adhesive strip. As soon as the picker is sent to position 1 via the NIMMSTA smart watch and the picker approaches position 1 within a radius of 10m, the smart watch and the light tag light up in the same colour and pattern. Based on the Freehand workflows and the pick-by-light solution with the light tags, the processes run up to 80% more efficiently, because the storage location is additionally immediately visually recognisable for the personnel. In the process, the wearable creates the conditions for up to a 50% percent increase in efficiency and the light tags contribute up to 30%.

Remarkably, no integration effort is required to use the system. Alternative pick-by-light systems are complex and costly to implement, both on the software side and the electronics or wiring at the racks. NIMMSTA’s pick-by-light solution is simple and smart: the intelligence is not in the display system, but in the industrial smart watch, which only addresses the corresponding light tag. With the help of this solution, processes can be transformed into freehand workflows.

IFOY test verdict: The potential for the solution in intralogistics and production is considerable. The provider’s goal is to optimize not just one process step, but the entire value chain. The focus is on creating more efficiency for the user, increasing process quality, and consequently securing the user’s productivity and growth. At the same time, however, the working environment of the personnel in intralogistics and production is to be improved.

IFOY Innovation Check

Market relevance: With increasing turnover figures in the mail order business, the topic of picking efficiency is gaining in importance. With the combination of “Industrial Smart Watch” with scanner as well as the “Light Tags”, NIMMSTA offers a cost-efficient solution to achieve a significantly higher picking speed than with handgun scanners when manually assembling consignments of goods. The market relevance is particularly high for small and medium-sized warehouses (in SMEs) where no investment in automation solutions is planned. However, the solution also scales into large warehouses and can pay for itself within 4 to 8 months.

Customer benefit: In addition to the 50% increase in efficiency already measured in customer applications using the wearable, the light tags are expected to improve search time at the shelf by a further 30% while reducing picking errors. Since the battery-operated light tags are only stuck to the shelf and integrated into the system with a one-time scan, setup is extremely simple and also very cost-effective compared to other solutions.

Novelty / Innovation: The combination of wearable with a pick/put-by-light solution without cabling effort and with very simple installation can be considered as a special novelty, which promises high efficiency increases in manual picking with very low investments and costs at the same time.

Functionality / Type of implementation: In terms of functionality, great importance was attached to simple usability in all relevant processes. Starting with the quick installation by simple sticking and one-time booking in the system, over the stringent user guidance via wearable and display of the next product by the light tags in the colours of the picker up to the replacement of the AAA batteries after the 3 to 5 years’ runtime in the tags for uninterrupted operation. The high battery life is achieved through extremely low-power communication strategies between the light tags and the wearable, and because no data processing takes place in the tags. By concentrating all intelligent functions in the wearable and via its cloud connection, a wide variety of other processes (goods receipt booking, inventory, stock transfer) can be added.

Verdict: The NIMMSTA pick-by-light solution enables a significant increase in efficiency of manual picking and putting processes, innovatively implemented through a technically simple display technology for the shelves in the warehouse that can be easily integrated by sticking and scanning. Due to the high level of user-friendliness, the comprehensive connection to a wide range of warehouse management systems and the very short payback period of usually a few months, the system is considered to have very high market potential.

Market relevance ++
Customer benefit ++
Novelty / Innovation +
Functionality / Type of implementation ++
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

IFOY Test Report: FFZ-KPI by Mobile Easykey

Posted on by David Priestman

In the run-up to the IFOY Award ceremony in Dortmund on June 22nd, Logistics Business features all the 2023 finalists and shares the verdict from the IFOY test conducted during the evaluation by an expert jury in March. Our latest entry is the FFZ-KPI software solution from Mobile Easykey.

With the Industrial Truck Key Performance Indicator developed by Mobile Easykey, users can see the performance of their intralogistics industrial truck fleet at a glance. This makes the time-consuming analysis of Excel tables and individual parameters a thing of the past. The Industrial Truck Key Performance Indicator is based on the OEE as an industry indicator for production plants. With the hardware and software developed, Mobile Easykey has expanded this industry indicator for moving machines and created a novelty in intralogistics analysis with the KPI.

IFOY category: Intralogistics Software

IFOY Test Report

The Industrial Truck, in German Flurförderzeug (FFZ), Key Performance Indicator, or FFZ-KPI for short, from the company Mobile Easykey enables the fleet efficiency of the intralogistics fleet to be determined at a glance. The prerequisites for this are a clear key figure and the easy-to-read visual traffic light system.

The FFZ-KPI is made up of four measurement parameters that are calculated together in an algorithm. The following are taken into account: the industrial truck is powered up, the industrial truck is logged on, the industrial truck is in use and the industrial truck is being driven with a load.

Fifty percent of logistics costs are based on the processes in a warehouse, and thus the industrial truck fleet also contributes a large share of the costs incurred there. The FFZ-KPI provides a manufacturer-neutral view of the performance of the fleet. It is manufacturer-independent, comparable and can be calculated on variable requirement parameters. When collecting the analysis data, the industry and the cycles of the processes on site are taken into account – because the process flows of a warehouse created on the drawing board vary greatly from warehouses that have grown organically. Reliable data can be collected per shift, per month, per fleet and also per vehicle or vehicle type.

From the collected data, clear conclusions can be drawn for fleet optimisation and future fleet deployment. Fleet managers and those responsible for the fleet can thus see the overall performance of the fleet at a glance. This is an important building block for making optimum use of the existing intralogistics fleet.

The FFZ KPI is based on the cross-industry OEE figure. This reflects the overall equipment effectiveness as a key business figure. The OEE figure is based on immobile plant and machinery. The FFZ-KPI adds further calculation parameters to the OEE key figure, which makes the key figure calculable for mobile plants.

IFOY test verdict: Intralogistics account for half of logistics costs and almost no warehouse can do without industrial trucks. However, the costs within intralogistics outside of the supply chain are often neglected because meaningful and clearly assignable data are missing. Consequently, there is great potential for savings in modern and efficient fleet management. The main advantages of the Industrial Truck Key Performance Indicator are the manufacturer-independent data and the possibility of cross-manufacturer data analysis. In addition, the KPI is easy to read due to the visual traffic light system. This makes the time-consuming analysis of Excel tables and individual parameters a thing of the past. The FFZ KPI is based on the OEE as an industry indicator for production plants. With the hardware and software developed, Mobile Easykey has expanded this industry indicator for mobile machines and created a novelty in intralogistics analysis with the KPI. Another important component is the cross-industry use of the KPI.

IFOY Innovation Check

Market relevance: The FFZ-KPI software is well suited for systematically evaluating the use of industrial trucks in larger fleets and visualising it in key figures. This provides the user with a data basis for drawing conclusions as to whether the availability and use of his trucks can be responsible for an influence on his operational effectiveness. In production companies, this is often referred to as overall equipment effectiveness (OEE). Since companies with significantly large fleets of FFZs and a focus on OEE are certainly relevant, but do not affect the overall FFZ market, the market relevance can be rated as good.

Customer benefit: The condensation and visualisation of the usage and availability figures is well solved for a regular application. The customisation options for individual usage profiles of individual FFZs and the design of the dashboard testify to a high level of competence in the development of user-friendly user interfaces. Overall, however, a high level of effort is required for data collection and aggregation, which is the basis for the determination of key figures. Overall, customer benefit can be rated as good.

Novelty / Innovation: Mobile Easykey has been offering the core functionality of the Easykey software for more than 20 years, which means that it is not new or innovative in the strict sense of the word. The software is the result of a consistently pursued evolution, which has led to a well-developed and contemporary software.

Functionality / Type of Implementation: The Easykey software offers the essential functions, properly prepared and user-friendly, to monitor large FFZ fleets and to condense key figures on their use and availability. It is technologically up-to-date, intuitive, and easy to adapt to the needs of different user characteristics and needs well.

Verdict: Mobile Easykey has been offering the core functionality of the Easykey software for more than 20 years, so it is not new or innovative in the strictest sense. However, the software is up to date and can be well adapted to the needs of different user characteristics and needs.

Market relevance +
Customer benefit +
Novelty / Innovation –
Functionality / Type of implementation +
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

 

IFOY Test Report: Loady by Loady

Posted on by Keith McKinley

In the next of our comprehensive looks at all the IFOY Award finalists ahead of the announcement ceremony in Dortmund on June 22nd, we put the Loady SaaS solution under the microscope.

Loady provides standardised, reliable requirements for loading and unloading at industrial sites for the first time. Trucks are no longer rejected at gates or loading points, because equipment and document to be brought along or processes to be known are communicated reliably and comprehensibly. A higher planning accuracy of transport services means savings of millions of euro to the industry and logistics service providers – and the constant troubleshooting on all sides finally comes to an end. Loady is fundamental to further digitise and automate logistics processes.

IFOY category: Start-up of the Year

IFOY Test Report

Loady is a Software as a Service (SaaS) solution and industry-wide reference source (single source of truth) for loading and unloading requirements that all logistics partners in the supply chain can refer to. For the first time, shippers and consignees can enter all the information and requirements that need to be considered for loading and unloading a truck at their location and for specific products into a standardised data structure.

The software includes a modular data model that can be used for complex, large sites and hazardous goods, as well as smaller and simpler goods deliveries. By assigning transport lanes, data can be shared with business and logistics partners for the respective operational processes. Data changes are tracked in the software, and there is a data history. This means that it is always possible to see which data status was valid at which point in time. Authorised business and logistics partners can be informed directly in the event of changes to relevant data fields. The data is used in the company applications via API, and there is also a mobile, multilingual interface for drivers.

There is no predecessor, just a long-standing breaking point that can be overcome with the software. Loady is the first solution on the market to manage loading and unloading requirements in a structured data model and be a reliable source for all logistics partners. The software is also the first centralised pre-product database.

Loady thus offers a meaningful alternative to free-text fields, in which companies currently try to track their requirements for loading, but also for unloading at their customers, in continuous text format, laboriously and sometimes incorrectly. In SAP, this mainly concerns the fields G12 and G14 in the forwarding orders. The software can also be used to replace manually compiled Excel files for logistics tenders, cleaning requirements and preliminary products.

Loady is relevant for all supply chain companies and their logistics service providers, Europe-wide and globally. This means a market volume of over 60,000 medium to large industrial companies and more than 20,000 logistics service providers worldwide.

IFOY test verdict: Industrial companies and logistics service providers benefit from Loady by providing reliable master data that is used along the processes. Responsibilities for relevant information are clearly defined. This is ensured by established data management roles with clear data governance rules. As a result, the risk of trucks being rejected at the loading or unloading point is also a thing of the past. In this way, the software helps to avoid extra or empty kilometres (reduction of carbon dioxide emissions). The effort required for problem solving, root cause clarification, data maintenance and mutual verification of information is reduced. Relevant changes are automatically communicated to business and logistics partners. This is associated with increased responsiveness, which leads to better understanding among all parties involved. Overcoming language barriers through a multilingual interface with direct translation for data managers, drivers and freight forwarders also contributes to this.

IFOY Innovation Check

Market relevance: Chemovator’s Loady product addresses the enormously important issue of standardised data exchange in the awarding and execution of transport orders in the forwarding environment, both in the industrial and the commercial environment. It thus provides “standardised and reliable requirements for loading and unloading at industrial sites” – undoubtedly a highly relevant problem for an extremely high number of companies today. There is almost no manufacturing company or trading company that is not affected by the issue.

Customer benefit: Standardised data storage and maintenance are already an enormous lever for error prevention. If necessary, this data is then also exchanged automatically and standardised on a case-dependent basis. This eliminates significant causes of errors and significantly increases process reliability. This does not only offer an advantage when all contractual partners of a process use the system, but already when one of the contractual partners has it in use, the first important advantages already become usable, through the then as free text, but nevertheless structured and standardised as well as previously checked provision of the data.

Novelty / Innovation: The problem, which is actually of far-reaching relevance, has simply not been addressed to date; it is the first solution of its kind. The market behaviour regarding the acceptance of data handling has not yet been fully clarified. The usability on the basis of different clients allows the product to be quickly implemented and accepted by users. The standard must be accepted as such by those responsible for the company.

Functionality / Type of implementation: The product is implemented with a convincing architecture, which also provides suitable clients with easy-to-use functionalities for the different user groups. Particularly is the conception, which already makes a significant advantage convertible also with initial few users. This makes a possible successful implementation profitable even in the initial phase for individual customers – a topic that is unfortunately often neglected in many products.

Verdict: At the interface between supply chain and intralogistics, this start-up is positioned in the area of loading. “The future standard” (own statement) offers a structured linking of data to optimise the overall process of freight from tendering to ramp approach. In addition, there is an architecture of applications up to an app for the driver. The challenge here is whether the proposed structure will actually be accepted as a new standard by stakeholders. However, the product can also function on its own, without another company being connected, and then outputs the data as free text, but in an optimised structure.

Market relevance ++
Customer benefit ++
Novelty / Innovation +
Functionality / Type of implementation +
[KEY: ++ very good / + good / Ø balanced / – less / — not present]

IFOY Test Report: Airrob by Libiao

Posted on by David Priestman

As we move inexorably towards the moment when the IFOY Awards are handed out in Dortmund on June 22nd, we continue our look at all of the 2023 finalists and share the verdict from the IFOY test conducted during the evaluation by an expert jury in March. Our next entry is the Airrob container handling robotic system from Zhejiang Libiao Robots Co., Ltd.

Zhejiang Libiao Robots invented the world’s first sortation robots five years ago; now they have created another new robotic system named Airrob container handling robotic system. The robots can climb racks, and store, pick, sort, and move plastic containers, and the climbing robot can move vertical and horizontal direction freely. It is a simple, efficient and flexible system for the fulfilment centre or the work-line-side storage system.

Category: Intralogistics Robot

IFOY Test Report

Libiao Robotics has been nominated for an IFOY AWARD with its Airrob, a “climbing” container robot. Its maximum load capacity is 25kg.

The system is suitable for the vast majority of all containers in this weight class, about 95% according to the manufacturer, and virtually all racks. It allows a quick and easy installation, even when retrofitting existing warehouses. Adjustments to the floor are not required. However, horizontal rails must be attached to the rack, over which the Airrob travels along the rack. The maximum speed of the robot is 2m/s.

The Airrob is attached to a lightweight frame that moves along the horizontal rails through the aisle. This design allows the robot to “climb” up the shelves and store or retrieve the correct container on the shelf at any desired location. Each bin is thus directly accessible at all times.

The frame is flexible and automatically adjusts to the position of the robot. This ensures high reliability and fast, trouble-free and stable transport of the boxes.

The system is suitable for racks up to 12m high. In this case, however, Libiao mounts two Airrobs on top of each other, as this requires less adjustment.

A unique feature is the hook system used to move the crates in and out of the racks. The hook moves within the contours of the robot, which does not penetrate the shelves. This allows the boxes to be stored extremely compact. The hook system is suitable for handling totes on both sides of an aisle. This limits the aisle width to about 85cm.

The concept is lighter than a miniload, a multishuttle or an autonomous case robot (ACR). This is one of the reasons why energy consumption is low. Consumption could not be measured by the IFOY test team, but according to the manufacturer, the savings compared to competing solutions is more than 30%.

The battery built into the Airrob is maintenance-free and is charged when the tablet is switched on and off; according to the non-sliding touch charging principle. The rack on which the Airrob is mounted is powered by mains electricity.

In the Pick&Go setups during IFOY TEST DAYS, the Airrob worked with the manufacturer’s AMRs, but other configurations are also conceivable.

The concept is particularly suitable for micro-fulfilment centres and can also be used in ambient temperatures as low as -20°C, for example in cold stores.

IFOY test verdict: The Libiao Airrob container handling system can set a new standard for mobile robots and fundamentally change existing solutions. The Airrob is cost-effective, scalable, and efficient. The system saves space and labour. The unique hook system guarantees high storage density.

IFOY Innovation Check

Market relevance: The Airrob solution addresses manually operated warehouses that are to be automated cost-effectively using existing racking infrastructure and potentially inhomogeneous container systems. With an ROI of one to two years for the 10 installations currently on the market, the Airrob system is an attractive option for brownfield automation in diverse industries such as warehouse logistics, e-commerce, or manufacturing. Airrob can be used for rack heights between approx. 2m and 14m and is already economical in smaller warehouses starting at 100 sq m. The market potential is high due to the high flexibility of the system, the comparably low costs, the wide range of applications as well as worldwide marketing partners.

Customer benefit: The greatest benefit of Airrob is its flexibility and adaptability for use in existing warehouses without replacing existing infrastructure. This also results in manageable investment costs, which should be a fraction of fully automated systems. Set-up and commissioning are in the range of one to four weeks. Due to the modularity, additional robots can be temporarily integrated for more throughput at peak times. Compared to similar solutions on the market, Airrob is said to consume 30% less energy. In addition, the system is easily reusable in other operating environments.

Novelty / Innovation: Airrob stands out for its simplicity of design, which enables high efficiency and robustness at low cost. Nevertheless, several innovative details have been implemented for the applicability in a wide range of manually operated warehouses. The vertical guide is flexibly mounted on two horizontal rails on the rack, so that even inclined shelves can be approached with the appropriate inclination. A simple hook mechanism allows access to various standard containers from two parallel shelves. Unlike comparable solutions, a fast-charging mechanism ensures 24/7 operation of the pick robot, so fewer pick robots are needed overall.

Functionality / Type of implementation: The pick robot, a type of stacker crane, is designed to be simple and practical, enabling a rapid access time of about 30 seconds to the totes weighing up to 25kg. The throughput of containers can be scaled flexibly by dividing the tasks between the pick robot on the rack and the mobile transport robots. With a temperature range between -20°C and 50°C, freezer applications are also possible.

Verdict: With Airrob, existing rack storage systems for any standard containers can be automated very cost-effectively. The easily retrofittable and technically minimalist solution for removing totes from heights of up to 14m, in conjunction with a fleet of mobile transport robots, enables significant efficiency gains compared to manual warehouse management. Technical highlights include the simple but universal gripper for crate removal and return, adaptivity to typical real-world conditions such as sloping shelf layers, and a fast-charging function for 24/7 operation.

Market relevance ++
Customer benefit ++
Novelty / Innovation +
Functionality / Type of implementation ++
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

IFOY Test Report: Jungheinrich addedVIEW

Posted on by Keith McKinley

As we move closer towards the moment when the IFOY Awards are handed out in Dortmund on June 22nd, we continue our look at all of the 2023 finalists and share the verdict from the IFOY test conducted during the evaluation by an expert jury in March. Our next entry is the second from Jungheinrich AG, its addedVIEW fork camera with barcode scanning.

The Jungheinrich addedVIEW fully digital fork camera with barcode scanning reduces storage/retrieval errors in the warehouse. It prevents incorrectly recorded goods or storage locations in the warehouse management system (WMS) and thus unplanned search times, returns or loss of goods.

IFOY category: Special of the Year

IFOY Test Report

In technical terms, the device is the first fully digital fork camera in series production, with full HD resolution, broadband automotive Ethernet data transmission and software for transferring the results to any WMS. For the Jungheinrich WMS, the product is equipped with additional intelligence that, with the help of coloured overlays in the camera image, makes it possible to recognise whether the correct or incorrect barcode is located in front of the fork as it passes by. In addition, an acknowledgement button is located near the steering wheel. This keeps the forklift driver’s hands on the controls of the industrial truck. The driver does not have to reach for the scanner, scan and put the mobile device back every time.

Scanning on-site at the storage compartment and/or the goods avoids scanning incorrect barcodes from a list at the rack foot, ensuring the WMS always receives correct data and avoiding incorrect deliveries. The high-resolution, digitally enhanced image allows labels to be read at high altitudes, bypassing the need to unstack incorrect merchandise.

By scanning with the fork-mounted camera, the location of the goods movement and the location of the scan coincide. This drastically reduces putaway/retrieval errors. Examples include putting away wrong goods but scanning the “right” barcode expected by the WMS, or taking out wrong goods but scanning the “right” barcode expected by the WMS. The camera, data transmission, image processing, forwarding to the WMS and, as in the case of Jungheinrich, the WMS itself were all newly developed or expanded – into an integrated series solution.

IFOY test verdict: The integrated series solution is unique on the market, because the addedVIEW fork camera with barcode scanning gets to the root of a previously unsolvable basic problem in logistics and offers a practical and effective solution. The previously described problem of incorrect storage is particularly pronounced in reach trucks, as mix-ups can occur in high-bay warehouses due to the large number of uniform storage locations and the low clarity in the upper rack levels. Depending on the type, 20-40% of reach trucks have tine cameras, are connected to a WMS via a radio data terminal and use handheld scanners for posting. These industrial truck operators will benefit from the innovation. But forklift drivers will also benefit from the image quality and the ergonomic acknowledgement function on the steering wheel.

IFOY Innovation Check

Market relevance: The management of goods on pallets or similar in larger warehouses with the help of reach trucks and barcodes concerns a very large area of logistics, which is why the market relevance is considered to be high. The presented digital camera-based system represents an enormous step towards the improvement of such systems, as errors are largely eliminated, positioning is supported and a large time-saving potential is associated with it.

Customer benefit: Users of the addedVIEW fork camera benefit in a very direct way from this system, which goes well beyond the camera itself by integrating it into the warehouse management system (WMS). Manual barcode scanning is no longer necessary, as direct identification of the barcodes is made possible by the high resolution of the camera. The comparison with the WMS, implemented in the background, provides direct information about the correctness of the goods or storage location. Thus, faulty storage or retrieval is reduced to a minimum or can be practically excluded. Furthermore, there are no wrong trips or unnecessary times in which incorrectly stored goods have to be searched for. All in all, this can result in a significant increase in the efficiency of the warehouse system for the user.

Novelty / Innovation: The integrated solution of a digital camera presented by Jungheinrich combines visual use with the possibility of scanning barcodes and processing them in the WMS for the first time in the field of material handling equipment. Although the individual technologies do not represent a novelty in themselves, the combination in this exemplary implementation is to be regarded as highly innovative. The challenges in the development, which in some respects reside in the details, were systematically solved. One example is the realised data transmission via the automotive Ethernet cable, which was applied to the variable geometry of the mast and which, with a total length of 30m, nevertheless guarantees a safe and fast transmission.

Functionality / Type of implementation: The components of the implemented system appear in a very robust design and thus meet requirements for durability in operation. The camera is mounted on the inside of the fork, which makes damage unlikely. Likewise, the transmission cable appears to be more than able to withstand the constant bending loads due to its specially developed design.

Verdict: The addedVIEW fork camera is convincing in every respect. Its market lead is clear.

Market relevance +
Customer benefit ++
Novelty / Innovation ++
Functionality / Type of implementation ++
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

IFOY Test Report: Jungheinrich PowerCube

Posted on by David Priestman

We turn our attention to the Jungheinrich PowerCube as we continue our look at all the IFOY Award finalists ahead of the announcement ceremony in Dortmund on June 22nd.

IFOY category: Intralogistics Robot

More efficient, faster and extremely flexible – as an automated compact storage system for containers, Jungheinrich says the PowerCube sets new standards in warehousing. Through vertical stacking of containers and time-saving storage, retrieval and transfer with high-performance lithium-ion shuttles, the easy-to-integrate warehouse solution ensures efficient processes, impressive space utilisation and a maximum increase in profitability in the era of e-commerce and just-in-time delivery.

IFOY Test Report

Since the storage and retrieval units of the PowerCube automatic compact tote storage system do not drive on top of the tote rack but underneath it, the height of the individual tote stacks can be easily adapted to the respective building infrastructure. Accordingly, it is possible to react to obstacles and, for example, adapt sloping roof shapes to the racking system, which can be up to 12m high.

Another important feature results from the 2D track system on which the shuttles perform their service. The system can be installed on standard industrial floors in accordance with DIN 18202, and floor unevenness can be levelled with levelling feet according to standards.

The maximum load of a container stack is 750kg. Containers designed for the application are used, which can take a load of up to 50kg. The maximum interior size of the containers is designed to allow the transport of standard KLTs (length x width x height: 600 x 400 x 290mm). Jungheinrich might roll out further container dimensions in the future. The PowerCube system containers are compatible with other automation solutions from the manufacturer and can also be used outside the compact storage system with the help of externally connected conveyor technology. Storage and retrieval stations or picking workstations have been implemented accordingly, but could only be visually inspected during the IFOY TEST DAYS, as could the entire system.

The newly developed shuttles move through the plant at a maximum speed of 4m/s and an acceleration of up to 2 m/s/s. The vehicles are designed for the simultaneous transport of two containers. In doing so, the shuttles are able to move automatically at the level below the rack. Since the shuttles operate at floor level, no platform is required to perform maintenance work.

With the help of appropriate relocations, the shuttles reach the containers required to process an order. During the relocations, which are limited due to the storage strategies used, another feature comes into play: The potential energy of the lifted container stacks is used for shuttle recuperation.

Shuttle charging stations are located at the workstations, but can also be installed at other locations within the plant. A fast-charging function creates the conditions for 24/7 operation of the warehouse system. A central element of the vehicles, the number of which can be adapted to the throughput requirements of the respective operator due to their scalability, is the lifting platform. This is shaped in such a way that the container is picked up positively and safely. Any positioning tolerances of the shuttle in both directions of transport can be compensated for by means of a compensation mechanism. As a result, reliable container handling is guaranteed at all times.

IFOY test verdict: Perfect use of space and time: This is how Jungheinrich defines the demands placed on the automated, compact and scalable PowerCube system. The pilot application, a retail company from Switzerland, will show whether the expectations are met. In any case, the potential is there.

IFOY Innovation Check

Market relevance: The market share of compact vertical storage systems has grown steadily over the past 10 years due to their broad applicability in production and retail with low storage space consumption. With the PowerCube, Jungheinrich is addressing a customer segment where storage heights of up to 12m with a variable height profile are desired, e.g., due to sloping ceilings. Since this applies to many existing buildings, the market potential of the solution is high. The economic efficiency is said to be given already from approximately 100 sq m storage area. The first pilot systems are currently being implemented.

Customer benefit: Due to the larger and more flexible warehouse height compared to market leader AutoStore, the PowerCube solution can achieve even better space utilisation. The robots operating underneath the store can transport up to two totes at higher speeds, making them more efficient. They can transfer totes more directly and with shorter access times (approximately two to three minutes) to output stations or conveyor systems. Maintenance is user-friendly at floor level. The installation time of less than six months is good but not exceptional, but extensions can be made almost without interruption during operation. Installation is possible without levelling the floor and different container heights can also be used.

Novelty / Innovation: Although the principle of the vertical compact storage system is not new and no serious differences to AutoStore are to be expected in terms of key figures such as compactness, throughput, costs and energy consumption, access from below is an innovation that permits new forms of use such as variable ceiling height and significantly higher storage bays and simplifies maintenance. Technical innovations in detail are the container loading weight of 50kg, an intelligently designed flap mechanism to hold the container stack in the shaft, a mechanical tolerance compensation for the container pick-up, and a quick-charge function for 24/7 operation of the robots without downtime.

Functionality / Type of implementation: PowerCube is a well thought out and high-quality solution with many potentials beyond the capabilities of AutoStore. The bins have been purposefully redesigned for the solution. Due to the operation from below, the maximum container stack weight is limited to 750kg, though. Energy recovery by the robots takes place during access. However, the system could only be inspected mechanically, not in operation. Use for refrigerated and frozen areas is in the works.

Verdict: The PowerCube vertical storage system, which has been implemented to a very high standard of quality, impresses with the possibility of flexible use of space thanks to variable heights of up to 12m and the use of the robots underneath the storage area, which results in easier maintenance and many options for dispensing goods from the system as well as a connection option to conveyor technology. A high throughput is achieved by the simultaneous pick-up of up to two totes with a load of 50kg each by one robot and its high speed.

Market relevance ++
Customer benefit ++
Novelty / Innovation +
Functionality / Type of implementation ++
[++ very good / + good / Ø balanced / – less / — not available]

 

IFOY Test Report: HUNIC SoftExo Lift

Posted on by David Priestman

It’s the turn of the HUNIC SoftExo Lift as we continue our comprehensive run-through of all the IFOY Award finalists ahead of the announcement ceremony in Dortmund on June 22nd.

Category: Start-up of the Year

IFOY Test Report

The passive exoskeleton SoftExo is an extremely lightweight but still effective body-worn lifting and carrying aid, developed for logistics and industry. Skilled personnel are supported with up to 21% when lifting and carrying loads, the body is relieved by up to 50% and the ergonomic posture is positively influenced.

High and prolonged strains, for example due to repeated lifting of heavy objects, pose a health risk for employees in production and logistics, which in the worst case can lead to an inability to work. According to the German Trade Association, every tenth day of incapacity to work in Germany is due to back pain.

This is precisely where the assistance system from HUNIC can provide preventive relief. The passive exoskeleton uses a spring principle to support the leg and back muscles when lifting loads and sensitises the user to ergonomic movement. Due to the adjustment options, the system can be worn by persons weighing from 50kg to 140kg, regardless of gender. In addition, all modules can be easily exchanged, cleaned in the washing machine and easily replaced when worn out. By optimising the working posture, the forces acting on the back are reduced by up to 50% and distributed evenly. In this way, the SoftExo Lift permanently relieves and protects the wearer’s spine, joints and muscles.

In addition, the tension of the leg support gives up to 21% more strength when lifting. Wearing the SoftExo Lift also improves the individual’s lifting and carrying technique, so that a lasting effect can be observed beyond the everyday working day. Users tire less and thus make fewer picking errors at the end of the shift.

With the help of the patented back rail, the spine is completely decoupled from additional load. No tensile forces are placed on the shoulder, causing additional strain on the intervertebral discs. The back splint also provides the user with haptic feedback if he or she slips into a hunched back or excessive twisting of the lower lumbar sector. Consequently, the user resumes an ergonomic posture. The user’s body is thus loaded according to anatomical ideals. Due to the integration of the knee joints, they are guided and supported by the laterally passing ligaments when squatting down. The enclosure of the sensitive joint avoids pressure points on the user’s thigh.

The SoftExo Lift by HUNIC does not require any external energy source, which thus excludes subconscious overloading of the human body. Due to the use of high-tech materials, the exoskeleton weighs only 1.4kg. At the same time, it lies close to the wearer’s body, which reduces the risk of collision with the environment.

IFOY test verdict: The SoftExo Lift permanently relieves and protects the user’s spine, joints and muscles. Wearing the exoskeleton from HUNIC on a regular basis sustainably improves the individual working posture towards an ergonomically more favourable posture. This creates the conditions for more comfortable work and ultimately for a better quality of life. Especially towards the end of the work shift, a reduced fatigue of the users can be observed. Due to reduced downtime and more motivated employees, the company gains an economic advantage. Consequently, the investment of €1,000 per exoskeleton is well worth it.

IFOY Innovation Check

Market relevance: The topic of exoskeletons or ergonomic body support is becoming increasingly important to continue to be able to work responsibly with people in industrial and commercial environments, even in times of significant demographic change. Humans still have superior capabilities compared to automated technology in certain areas and activities, which can be brought to greater efficiency and productivity at high quality with technological support. Nevertheless, the fields of application of exoskeletons are still manageable so far.

Customer benefit: The deliberate conversion to a support instrument that is easy to wear and less annoying significantly increases acceptance. By consciously pointing out incorrect movements through the product, physical overloads and thus damage are avoided at an early stage. An increase in performance is often the result. The adaptation of the product to different areas of activity allows targeted use and thus the optimization of very specific physical activities.

Novelty / Innovation: It is a completely passive exoskeleton that also has few solid areas that would negatively affect wearing comfort and thus be detrimental to acceptance. The very great innovative leap therefore lies on the one hand in the design of the exoskeleton from purely soft, elastic materials, without neglecting the support function. Furthermore, it is the targeted pointing out and thus prevention of incorrect movements. In addition, the exoskeleton is prepared to accept sensors (e.g. from the IFOY nominee Predimo) for process monitoring and optimisation, for movement optimisation and for increasing occupational safety.

Functionality / Type of implementation: The exoskeleton is of very high quality. As mentioned, the focus is on high wearing comfort and thus acceptance by the user. Through the connection with sensor technology, it allows a significant optimisation of processes towards more safety and health in the future. Particularly noteworthy are the different versions for different activities with adapted, very intelligent features.

Verdict: This start-up takes up the exoskeleton theme, in a novel, soft version. Support for certain movements is available but is not the focus. Wearing comfort of the exoskeleton and especially showing wrong movement patterns are the focus. In addition, various features will be integrated for different sectors (e.g., a handle for patients in the nursing sector to support lifting. It will also be possible to attach sensors and evaluation units to the exoskeleton to implement optimisation and monitoring.

Market relevance Ø
Customer benefit +
Novelty / Innovation +
Functionality / Type of implementation +
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

IFOY Test Report: IdentPro Warehouse Execution System

Posted on by Keith McKinley

As the clock ticks towards the moment when the IFOY Awards are handed out in Dortmund on June 22nd, we continue our look at all of the 2023 finalists and share the verdict from the IFOY test conducted during the evaluation by an expert jury in March. Our next entry is the Warehouse Execution System from IdentPro.

Category: Intralogistics Software

IFOY Test Report

Not only the increasing shortage of employees, but also the global challenges of the supply chain are increasing the pressure on automation in intralogistics. While significant levels of automation have already been achieved in the production processes, there is still great potential in the connected warehouses. The IdentPro digitisation solution creates the necessary prerequisite for this. A digital twin is created in real time (RTLS), in which every single transport of a good is consistently and automatically tracked to the centimetre using Lidar technology. For this purpose, all existing vehicles (manned, automated, manufacturer-independent) are equipped with IoT sensor technology, which thus permanently record up-to-date 3D information about the movement of the stored goods as well as the surrounding spatial geometry.

Via Wi-Fi or LTE, the system is in constant exchange with all the industrial trucks in use. This allows empty runs, search times and inefficient storage scenarios to be analysed. This data forms the input for intelligent algorithms. Intelligent allocation of driving jobs in real time with efficiency increases of between 20% and 30% are the result.

The IoT solution has several USPs that stand out in interaction with each other: real-time digital twin of the warehouse (RTLS), centimetre-precise localisation (+/-10cm) of goods and vehicles, collaborative use of autonomous and manned industrial trucks, and smart distribution of driving orders (SLS). All this is combined in the software solution, which ensures transparency and overall system effectiveness in intralogistics through interfaces and standards (such as omlox and VDA 5050). Connections to ERP systems or WMS are additionally possible at any time.

The Warehouse Execution System, in combination with reliable laser technology, generates complete transparency in real time. In contrast to other solutions via RFID, UWB or camera, the IdentPro solution is characterised by the centimetre and millisecond accurate creation of the digital twin. The use in open areas can be realised without further ado. Furthermore, the solution does not require any change in the infrastructure of the warehouse. Only the existing industrial trucks need to be equipped with IoT sensor technology. The software can be used directly in the inventory.

IFOY test verdict: With the digital twin in real time, IdentPro sustainably increases the overall system effectiveness of intralogistics. The warehouse execution system creates full transparency, ensures inventory security and error-free deliveries, increases efficiency, navigates loaded and unloaded vehicles in collaborative use, and can be used indoors and outdoors. Based on the complete data situation, not only does productivity increase, but the basis for smart automation is also created. Only with the twin technology can both unmanned and manned vehicles be orchestrated and controlled from one system. The supplier’s Warehouse Execution System fits seamlessly into the user’s circumstances and leads to efficiency increases of up to 30%.

IFOY Innovation Check

Market relevance: A high market relevance is seen for the presented solution of the Warehouse Execution System. The mapping of warehouse geometry, including the localisation of various manned and unmanned material handling vehicles, is useful in a wide range of sectors, as an increasing shortage of skilled workers is to be expected across the board. The approach of IdentPro GmbH can be an essential component to advance digitalisation in a company with an increase in efficiency or even to introduce it in the first place, which results in a large number of potential customers.

Customer benefit: By using the Warehouse Execution System, customers can achieve a significant increase in efficiency and at the same time enable and control the use of autonomous vehicles. Depending on the requirements, savings in personnel are then possible without detaching the warehouse employees or operators of manned industrial trucks from the warehouse processes. The digital image of the warehouse includes not only the vehicles but also the warehouse stock and thus provides full transparency, whereby the individual transport orders can be processed efficiently and comprehensibly in real time. The most flexible possible implementation of the system at the customer’s site, independent of the warehouse layout, makes it very easy to achieve the customer benefits, such as the avoidance of errors or empty runs and thus the increase potential in efficiency.

Novelty / Innovation: The generation and utilisation of a digital twin in this practice-oriented manner, with the implementation of a wide variety of material handling equipment and warehouse management, undoubtedly has a high degree of innovation. The uncomplicated possibility of applying the system to existing warehouses and optimising and monitoring the transport routes calculated in real time, as well as integrating stock and orders, appears to be a sensible new approach to meeting the increasing demands in terms of market leadership.

Functionality / Type of implementation: The system’s processes were impressively demonstrated. It became clear that the use of sensors was reduced to a sensible minimum, which makes the integration of existing vehicles relatively simple. Similarly, the determination of the transport routes was realised in a practice-oriented manner via optimisation algorithms, for example with the target value of minimum time.

Verdict: A worthy IFOY nominee with a clear market lead.

Market relevance +
Customer benefit ++
Novelty / Innovation +
Functionality / Type of implementation ++
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

IFOY Test Report: Hikrobot F4-1000C

Posted on by David Priestman

In the next of our comprehensive looks at all the IFOY Award finalists ahead of the announcement ceremony in Dortmund on June 22nd, we come to the first of several entries from China, the F4-1000C AGV from Hikrobot.

Category: Automated Guided Vehicle (AGV / AMR)

IFOY Test Report

Hikrobot introduces the F4-1000C, or F4 for short, a super-compact AGV designed specifically for use in narrow aisles or confined spaces. It can be used in a variety of conditions, from logistics to production environments. With a chassis of just 400mm (1,600mm including forks) and a width of 800mm, the IFOY nominee appears extremely slim. Despite its compact size, the AGV with forks can effortlessly transport and lift loads of 1,000kg up to a height of 1.3m. At the maximum lifting height of 3m, the residual load capacity is 600kg.

With travel speeds of 1.8m/s (without load) and 1.2m/s (with load), the robot is faster than many competitors. Lifting speed is 0.5m/s (unloaded) and 0.3m/s (loaded). Lifting accuracy is ±2mm.

The CE-certified F4-1000C is equipped with numerous safety features that ensure safe cooperation between man and machine. It operates precisely and reliably with a positioning accuracy of ±5mm. At the IFOY presentation, the F4 detected pallets that were not fully in position thanks to the camera in the fork carriage. If a pallet deviates by up to 10°, the AGV detects this and independently corrects its position.

Hikrobot’s in-house fleet management system can also be easily adapted to the requirements and systems of customers in different industries. No third party is required for this, eliminating additional work and costs.

The F4-1000C is controlled by Hikrobot’s robot control system (RCS). This system optimises routes and avoids congestion and traffic delays. According to Hikrobot, this increases efficiency by two to three times.

The F4 navigates with SLAM technology. The 48V/70Ah lithium-ion battery is sufficient for eight hours of use on a full charge, according to Hikrobot.

Regardless of the workflow or deployment situation, the F4-1000C ensures a smooth flow of goods. The F4 is one of the few robots that can operate in both logistics environments and industrial deployment situations. The F4’s “mother tongue” is Italian, but it can provide feedback in all European languages.

The manufacturer considers the attractive price to be a major plus point. Since the Chinese manufacturer  ̶  with the exception of the SICK sensor  ̶  develops and produces all components in-house, Hikrobot retains maximum control over the supply chain. In addition, this allows the manufacturer to respond to a wide variety of customer requests and requirements. In other words, maximum flexibility at a competitive price. By its own account, Hikrobot delivers the F4 at a price that is at least 30% lower than any competitor. To maintain control of the supply chain after delivery, Hikrobot has a European headquarters and spare parts centre in Hoofddorp, the Netherlands.

IFOY test verdict: Thanks to its compact size, the independent F4-1000C maximises the use of storage space. Its manoeuvrability gives users a great advantage in both logistics and industry.

IFOY Innovation Check

Market relevance: Vehicles like the F4 1000C with a fork for standard pallet skids have a large market. The 1200x800mm pallet format and other load carriers with these basic dimensions, such as mesh boxes or large load carriers, are used in very many companies in Europe.

Customer benefit: The extremely compact design of the vehicle with a short body for drive and control results in a vehicle length of only 1640mm. This enables the F4-1000C to place the DIN pallet format 1200x1000mm crosswise in a rack after a 90° turn, even in a storage aisle that is only 2052mm wide. The manoeuvrability of the compact vehicle enables a good utility value for the user.

Novelty / Innovation: Even in this compact design, the vehicle is not exceptionally new. Market competitors already have vehicles with omnidirectional drive in their portfolio, which currently represent the benchmark in the compact industrial truck segment.

Functionality / Type of implementation: In addition to its compactness, the F4-1000C offers many good functions and features that are beneficial to the user. These include the autonomy functions, such as the well-functioning avoidance of obstacles. The demonstration of detecting load carriers outside the specified pick-up position, for example twisted or shifted, did not work in the successive tests.

Verdict: Vehicles like the F4 1000C have a very large market, as the 1200x800mm pallet format is used in very many companies. The manoeuvrability of the vehicle enables good benefits for the users. Even in this compact design, the vehicle is not exceptionally new, but offers good functions and features for the user.

Market relevance ++
Customer benefit +
Novelty / Innovation Ø
Functionality / Type of implementation +
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

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