RTLS Asset Metering for Vehicle Throughput Bottlenecks
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Solution Overview
Problem
Vehicle tracking and management systems face inefficiencies due to bottlenecks in processing areas, leading to excess inventory and delayed vehicle throughput, as they lack effective control mechanisms to manage asset flow and availability in real-time within manufacturing environments.
Innovation Solution
A system utilizing a real-time location system (RTLS) with tag transmitters and processors to optimize asset flow by determining input rates, predicting asset availability, and controlling the rate of asset injection into processing areas, thereby managing overflow and identifying bottlenecks through predictive and rate control metering models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If processing areas operate at maximum speed without control, then processing capacity is improved, but excess inventory and bottlenecks occur downstream
Solution Approach 1:
The system implements real-time feedback loops where RTLS tracking data on asset locations and processing status is continuously fed back to the processor. The processor uses this feedback to dynamically adjust input rates into WIP, ensuring that processing areas operate at optimal speeds without creating downstream bottlenecks or excess inventory accumulation.
Solution Approach 2:
The system performs preliminary actions by predicting future asset availability and processing requirements before they occur. The processor calculates predicted asset availability and adjusts input rates in advance, preventing bottlenecks and excess inventory formation before they happen rather than reacting after problems arise.
2Productivity
If RTLS tracking and predictive metering are implemented, then asset flow optimization is improved, but system complexity increases
Solution Approach 1:
The processor serves multiple functions simultaneously: it receives RTLS tracking data, predicts asset availability, calculates input rates, and controls asset flow into WIP. The RTLS infrastructure also provides both location tracking and flow optimization data. This multi-functionality reduces the need for separate dedicated systems for each function.
Solution Approach 2:
The processor acts as an intermediary between the RTLS tracking infrastructure and the asset flow control system. It translates raw tracking data into predictive metering decisions and rate control commands, simplifying the integration between tracking and control functions while managing the overall system complexity.
3Loss of information
If real-time location tracking is used, then asset location visibility is improved, but measurement and detection difficulty increases
Solution Approach 1:
The system creates a virtual copy of the physical asset locations through RTLS tracking. Instead of physically monitoring each asset, the system uses electronic representations (tags and tracking data) to replicate location information, making asset visibility achievable through data copying rather than direct physical measurement.
Solution Approach 2:
The system replaces complex mechanical tracking methods with electronic RF-based RTLS technology. Instead of using physical markers, mechanical sensors, or manual tracking, the invention uses wireless radio frequency tags and electronic signal processing to detect and measure asset locations, simplifying the detection process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces excess inventory, improves labor productivity, and enhances vehicle throughput by optimizing asset flow and managing bottlenecks in real-time, ensuring efficient processing and reduced dwell times within manufacturing environments.
Implementation Method 1
A plurality of assets such as vehicles have a tag transmitter associated therewith and operative for transmitting a wireless RF signal that includes data relating to the identification of the asset
Implementation Method 2
The processor is operative for correlating a signal as a first-to-arrive signal and conducting differentiation of first-to-arrive signals to locate an asset
Implementation Method 3
The processor is operative for correlating a signal as a first-to-arrive signal and conducting differentiation of first-to-arrive signals to locate an asset
Data Source
AI summary
A system and method optimizes throughput of tracked assets as work-in-progress (WIP) within a monitored environment such as a manufacturing establishment with off-line processing areas. A plurality of assets such as vehicles have a tag transmitter associated therewith and operative for transmitting a wireless RF signal that includes data relating to the identification of the asset to which the tag transmitter is associated. A real-time location system (RTLS) infrastructure tracks the location of the plurality of assets to various containment, staging, and processing task areas within the monitored environment as WIP. A processor is operative with the RTLS infrastructure for determining an asset input rate into WIP at an origin to the WIP for optimizing asset flow rate as WIP through different containment, staging, and processing areas within the monitored environment.