Real-time production planning: AI-supported control of the material flow

The digital twin provides real-time data for transparent planning processes in the production-related warehouse. This allows AI-supported decisions to be made that optimize internal transport processes – with synergy effects along the entire supply chain.

Our future is determined by data: it is the key to greater efficiency in all areas of life. Even in production planning and warehouse logistics, data packets are becoming increasingly complex. This is because raw materials must arrive at the processing location at the right time and in the exact quantities required to ensure a smooth flow of materials. In between, there are many facets in the production-related warehouse: semi-finished products are removed from storage, transported to the next production step or taken to another warehouse on site. The processes are therefore subject to a tight economic framework. Innovative logistics concepts in the global markets of industrial production must also deal creatively with the increasing shortage of skilled workers in a complex world. Technological progress gives us access to more and more data. The aim is to always make the best decisions in terms of optimal production planning. Where human processing capacity for more efficient warehouse processes ends, the triumphal march of artificial intelligence begins in automated intralogistics. “Our primary goal is to bring full transparency to the warehouse,” says IdentPro Managing Partner Martin Welp.

Real-Time Data Processing

Real Time Data Processing

Optimized Decision-Making

Optimized Decision Making

Efficient Warehouse Processes

Efficient Warehouse Processes

Reduced Error Rate

Reduced Error Rate

Cost Efficiency and Sustainability

Cost Efficiency And Sustainability

Resource Management

Resource Management

Synergies along the Supply Chain

Synergies Along The Supply Chain

Digital twin delivers data packets in real time

A requirement for transparent warehouse processes is that all processes are documented: IdentPro ensures that every product that is moved on the company premises is digitally captured in its position. Enriched with all other available information on the order, the GEO position or the destination, which is fed into the software from the connected systems such as ERP or WMS, a data packet is created: the digital twin. In the digital world of automated warehouse logistics, data packets are now delivered without delay.

Data as a valuable source of inspiration for AI-supported decisions

The more data that is available, the greater the potential for decision-making. Only good decisions are the perfect basis for optimized processes. Where the human brain and Excel spreadsheets are limited in their processing capacity, artificial intelligence fed with this data calculates the most efficient processes in the shortest possible time.

“Our intelligent warehouse logistics concept equips forklift trucks with a trajectory-based laser system for this purpose,” says Martin Welp.

The scanned data from the LiDAR and IoT sensors on the warehouse situation is converted into GEO data by the IdentPro software. In this way, all warehouse processes are mapped as a digital twin in real time. The software is AI-based and reports back on how internal transport can be optimized. The digital twin is also available to all other systems. In this way, the IdentPro Warehouse Execution System enables optimal raw materials management synergies along the entire supply chain.

Optimization potential with the IdentPro Warehouse Execution System:

  • Real-time localization
  • Live mapping accurate to +- 10cm
  • Consideration of dynamic storage changes
  • Scan-free warehouse processes
  • Paperless administration
  • Empty runs are reduced
  • Warehousing with minimum stock

Zero error tolerance: to prevent the error bug from roaming the supply chain

In industrial production, raw materials must always be on time. The error tolerance in production planning is low, as the error continues along the supply chain and leads to high financial losses. “Even if only 0.4% of the scans carried out in the warehouse were incorrect, this would result in an error with 200 movements per day that would continue along the supply chain,” calculates Martin Welp. In 30 days, for example, that would be 30 faulty pallets that need to be searched for and reintegrated into the supply chain.

“The costs that can be saved with automated, error-free AI decisions are considerable.”

Where drivers previously had to get off the forklift to document warehouse movements using a clipboard or scanner and enter the production environment under appropriate safety precautions, the sensor system with IdentPro records all data and reports errors back instantly. This means they can be corrected on the spot. Drivers do not need to know the site for this, as the system uses navigation to show the route to the product to its exact position in the warehouse and automatically maps every warehouse movement digitally.

Transparency in real time: ensuring that every stock movement is correct

The digital twin is the virtual representation of the physical warehouse: it provides real-time data on the condition, inventory and activities. Its analysis and processing can be used in many ways to optimize processes. IdentPro uses the digital twin to create transparency in the warehouse in real time and to optimize internal transports.

This makes it possible to operate more efficiently, reduce costs and minimize the carbon footprint. Inventory is managed more effectively, space utilization is optimized, bottlenecks can be avoided and manual errors reduced. Delays and incorrect deliveries are a thing of the past with the digital support. Clipboards and hand scanners can be eliminated in the paperless warehouse. Forklift drivers can be trained more quickly thanks to automated processes and driverless transport systems can close personnel gaps in the shortage of skilled workers.

Advantages of AI in warehouse logistics:

  • Efficient planning of routes
  • Reduce costs
  • Minimize CO¬≤ footprint
  • Optimize warehouse management, inventories and space utilization
  • Avoid delivery bottlenecks and production interruptions
  • Reduce manual errors
  • Paperless warehouse
  • Reduce human resources

The future of AI-supported production planning starts now

The future of intralogistics lies in AI-based, networked planning: In an ideal world, everything in raw materials management is precisely timed. But that’s not how the complex global situation works. If there are delays in the supply chain, this leads to delivery bottlenecks, excess stock or waste, and in any case to skyrocketing costs. Optimum supply chain management requires transparency in the warehouse: the better networked the supply chains are, the more efficiently goods can be moved. To achieve this, different systems need to work closely together under the heading of interoperability. Then there will no longer be a process that does not have a digital twin, says Martin Welp, looking ahead. Artificial intelligence will be essential in the future due to the high density of data. He also sees in-house transportation becoming increasingly driverless in light of the shortage of skilled workers. Martin Welp adds: “The future of production planning begins now: Because the technical prerequisites for the delivery of data packets in real time along the entire supply chain with automated AI-based decisions are already in place.” 

Do you want to digitize your warehouse, gain more transparency and exploit the full potential of your resources?

We at IdentPro support you in this endeavor and would like to shape with you the future of intralogistics. Schedule a personal consultation now!

IdentPro on social media