RTLS Applications and Case Studies Manufacturing Process Energy

RTLS Applications and Case Studies Manufacturing Process & Energy Public Transport Agriculture Military Events & Entertainment Logistics Research & Other

ustomer Reference C Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other BMW Car Plant Regensburg, Germany (Final Assembly Tool Assistance) Installed area: 1. 7 km assembly line | Sensors: 350 | Accuracy: 30 cm in 3 D | Events/day: 150000 | Reliability: 99. 99% Problem Different models of car are produced on the same line necessitating loading a different tool program into the power tools based on the specific vehicle to be worked upon. Previously the identification of the vehicle occurred using a barcode scanner resulting in unproductive work (~6 seconds per tool op. at 150 tool stations on 1, 000 cars per day). The Ubisense solution Production Management System Ubisense Tool Assistance IBS Tool Controller Vehicle - Tool association DC Tooling The Ubisense system tracks both vehicles and tools detecting when a tool is brought close to the vehicle. The required tool program is obtained from the MES using the VIN and sent directly to the IBS Tool Controller to program & enable the tool. The system solution was jointly developed by Ubisense and IBS. Result Cost and time reduction on the line and quality improvement by excluding human error and re-work. Unproductive time saved reduces costs by many $100, 000‘s. 2 Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other Aston Martin Car Plant Gaydon, UK (Finishing Process Tracking) Installed area: 11700 m² | Sensors: 58 | Accuracy: 50 cm in 2 D | Reliability: 99. 9% Problem As cars come off-line into the finishing area, they can miss process steps leading to rework or become ‘stuck’ in a step creating inventory build up. The Ubisense solution The Ubisense system tracks the vehicles as they come ‘off-line’ and move through specific process stages (rolling road, wheel alignment, paint inspection, etc. ). Defined rules specify the process order and dwell time thresholds (time spent in a step). Exceptions trigger alerts visible to shop-floor operators and reported on intranet. Enterprise Intranet Ubisense Process Tracker Result Time reduction and Work In Progress (WIP) throughput improvement as cars are always visible through the finish and rework process. Reduced rework and improved quality. 3 Vehicle - Bay /Area association & process rules Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other Honda Motorcycle Plant Atessa, Italia (Component Process Tracking) Library Images Installed area: 2000 m² (75 m assembly line) | Sensors: 13 | Accuracy: 30 cm in 3 D | Reliability: 99. 9% Problem The production process required manual barcode scanning of printed VIN labels at each station in order to call up the specific task list. In addition, there was no traceability of major components. The Ubisense solution IBM LAS Ubisense Location Platform Passive RFID Motorcycle & Components Tracking Frame Identification The Ubisense system tracks vehicles on the line enabling automatic identification of required tasks at each station (via interface with Production Planning System). In addition, major components are tracked and associated with specific vehicle to provide automatic traceability and replenishment signaling. Result Process optimization and error reduction on the line has increased productivity and quality. In addition inventory replenishment has been improved and component traceability means long term quality and customer satisfaction will be improved. 4 Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other Ortrander Iron Foundry Ortrand, Germany (Material Flow Tracking) Installed area: 2000 m² | Sensors: 11 | Accuracy: 30 cm in 3 D | Reliability: 99. 9% Problem The content (number and type of part, status in production cycle) and location of containers was not visible centrally in the production control system. This resulted in delays fulfilling customer orders since it was not known whether or not sufficient quantities of completed parts were available. The Ubisense solution Ortrander PPS Ubisense Location Platform Passive RFID & Weighing Sys. Forklift Tracking Material Identification & Weighing The Ubisense RTLS continuously tracks forklift movements whilst the Spatial Platform maps processing stations and storage locations as hot-zones and combines these with the pallet ID determined via passive RFID reader and the results of the on-fork weighing system. As pallets are slotted the PPS is informed, so it knows the specific ID and location of pallets at all times and can update the process stages of orders automatically in real-time. Result Increased productivity, reduced cost & dwell time, faster fulfillment of customer orders. 5 Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other Caterpillar Equipment Plant Gosselies, Belgium (Assembly Tool Control) Installed area: 400 m² | Sensors: 8 | Accuracy: 30 cm in 3 D | Reliability: 99. 9% Problem The assembly of the hydraulic valves at the heart of Caterpillar construction vehicles is performed using torque wrenches to fasten reinforced tube hoses to the valves. The tightening of a bolt that fastens a hose to a valve must be applied with a specific amount of torque – around 300 Newton meters (Nm) – in order for that valve to operate properly. Caterpillar’s quality standards demand 100% traceability of correctly tightened hoses. De. Jaeger Protrac (PMS) Ubisense Location Platform De. Jaeger Tool Control Valve - Tool association DC Tooling The Ubisense solution The Ubisense system tracks wireless electronic wrenches, detecting when the tool is brought close a valve assembly station. Each wrench is designated for a specific assembly station, and is preset to tighten a specified amount. The location information ensures that each wrench is being used at the correct station when the quality data is collected. Result Increase in correctly assembled valves and hoses leading to less rework on leaking valves. 6 Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Bath Iron Works Shipyard Maine, USA Military Events & Entertainment Other (Asset Management) Installed area: xxx m² | Sensors: 54 | Accuracy: 100 cm in 3 D Problem Finding / tracking assets and tools on the dock and inside buildings. Assisting in the completion of audits for government owned equipment The Ubisense Solution Long range sensors tracking tagged assets between ships. Combination of wired and wireless sensors working indoors and outside in very harsh conditions Accuracy delivered 1 – 1, 5 m Enterprise Intranet Ubisense Asset Tracker Results Improve efficiency by reducing search times. Improve production times and reduce time to complete government audits Asset & Tool Tracking 7 Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other Cummins Engine Plant Jamestown, USA (Test Process Monitoring) Installed area: xxx m² | Sensors: 76 | Accuracy: 30 cm in 3 D | Reliability: 99. 9% Problem Searching for engines throughout the repair, test and shipping areas was taking too long and slowing down production cycle time and requiring extra staff. The Ubisense Solution Tags are scanned, associated with and attached to engines as they enter the repair or shipping areas. Engines then are tracked and every time an engine enters or exits a work cell the exact time is recorded in a standard database and passed into the Allen-Bradley PLC. In addition their location can be determined via a web browser. As engines leave the plant, tags are removed in the shipping office and automatically disassociated from the engines they had been attached to. Result Continuous automated monitoring processes leading to higher throughput. Search time for engines has dramatically decreased (in the repair area search time has decreased by 98%) 8 Allen-Bradley PLC Ubisense Process Tracker Engine - Bay /Area association & process rules Case Study © by Ubisense 2009

Manufacturing Process & & Energy Process Public Transport SMDK Kölliken, Switzerland Logistics Agriculture Military Events & Entertainment Other (Personnel Security) Installed area: 11000 m² in phase 1 | Sensors: 42 | Accuracy: 100 cm in 3 D Problem At the toxic waste dump in Kölliken (SMDK), chemicals are leaking into the groundwater and threatening the drinking water supply. Therefore the local government ordered the complete dismantling of the dump which is being carried out in 2 phases. As contaminated materials are removed, a “black” area had to be erected, consisting of a hall preventing the escape of toxic dust, gas and odours. Worker safety is a primary concern and escape tunnels proved impractical for both engineering as well as cost reasons. Ubisense Location Platform The Ubisense Solution Each worker wears a Ubisense Tag on their helmet. The tracking system enables the Arge Phoenix management to know the precise whereabouts of all workers within the site's "black" areas so it can maintain a precise head count in case of a fire or other emergency, and rescue any employees having difficulty escaping to safety. Personnel Tracking Results Greatly improved worker safety in the “black” area. 9 Case Study © by Ubisense 2009

ustomer Reference C Manufacturing Process & & Energy Process Public Transport Logistics Areva NP Archive Erlangen, Germany Agriculture Military Events & Entertainment Other (Personnel Security) (1) (2) (3) (4) (5) (6) (7) Automated Alarm Manual Alarm System Acoustic Equipment Optical Equipment Gas Container Nozzles Installed area: 1800 m² divided up into several rooms | Sensors: 34 | Accuracy: 100 cm in 2 D Problem Plans and related building documents for nuclear reactors are stored in the Areva NP central archive for up to 90 years in acc. with government regulations related to nuclear facilities. In order to prevent loss or damage from the use of conventional extinguishers, a system is installed which floods the archive with nitrogen in case of fire. In such a situation, it is imperative to be able to immediately locate all personnel currently in the archive precisely and reliably to facilitate rapid rescue and evacuation. Ubisense Location Platform The Ubisense Solution Visitors and employees are registered and supplied with a Ubisense tag upon entry into the archive. The integrated Ubisense 3 D Visualization provides a graphical indication of where the personnel are at all times. In addition an associated list is maintained, displaying in real-time exactly in which areas how many staff are located. Personnel Tracking Results Greatly improved worker safety in the archive. 10 Case Study © by Ubisense 2009

ustomer Reference C Manufacturing Process & & Energy Process Public Transport Logistics Agriculture BNFL Nuclear Power Facility Sellafield, UK Military Events & Entertainment Other (Personnel Security) Installed area: 100 m² | Sensors: 8 | Accuracy: 30 cm in 3 D Problem Sellafield is one of 20 aging U. K. nuclear facilities being decommissioned. Employees involved in decommissioning and clean-up within the facility are exposed to fluctuating radiation. It is vital to ensure that the amount of radiation to which they are exposed during any one work period remains below the specified limits. The Ubisense Solution BIL Solutions Ubisense Location Platform Radiation Dosimeters Personnel Tracking Radiation Measurements Employees carrying out work assignments at the power plant wear both Ubisense Tags and Wi. Fi dosimeters, which measure radiation levels. BIL Solutions' software provides views of the facility, with radiation levels depicted in different colors combining location data from the Ubisense RTLS with the radiation readings. Workers' dose histories are monitored real-time as an aid to scheduling their work in the plant. Results The radiation maps and real-time exposure records significantly improve worker safety and efficiency of the operation. 11 Case Study © by Ubisense 2009

Manufacturing Process & & Energy Process Public Transport Logistics Agriculture Military Events & Entertainment Other BP Refinery, Germany (Personnel Safety Pilot Installation) Installed area: Perimeter around 22000 m² | Sensors: 22 | Accuracy: 150 cm in 2 D Problem Safety monitoring of personnel in hazardous environments. The Ubisense solution The Ubisense RTLS network covers the perimeter, access paths and strategic internal junctions and tracks staff wearing tags on their helmets as they walk around the enclosed area. The Spatial Platform creates hot zones around hazardous plant to provide visual safety alerts. Ubisense Location Platform Result Real time location visibility and zone-level monitoring of personnel Automatic notification of unauthorised entry into safety critical zones Increased safety and process compliance Personnel Tracking and Identification 12 Case Study © by Ubisense 2009

ustomer Reference C Manufacturing Process & Energy Public Transport Logistics VBL Bus Depot Luzern, Switzerland Agriculture Military Events & Entertainment Other (Depot Management) Installed area: 15000 m² in 1 depot | Sensors: 48 | Accuracy: 100 cm in 2 D | Reliability: 99. 9% Problem Management of the workflow in a bus-depot is an important issue today. Knowing, if a bus enters or leaves a depot as well as the position of the each bus inside a depot is fundamental for efficient planning and dispatching. The Ubisense Solution Swiss Axis Be. Dips Ubisense Location Platform Each of the 160 buses of vbl is tagged, allowing the Ubisense platform to determine time stamps of incoming and outgoing buses and an exact bay, lane, and position of each bus, as soon as it is parked inside the garage. The online-interface to the Swiss Axis Be. Dips Depot Management System enables dispatchers to efficiently schedule and organise the parking, maintenance and refuelling processes in the depot. Results Correct, fast and reliable dispatching, correct invoicing of the work in a depot (maintenance, cleaning and preparation for the daily use) 13 Bus Tracking and Identification Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other Je. Nah Bus & Tram Depots Jena, Germany (Depot Management) Installed area: xxx m² over 2 depots | Sensors: 104 | Accuracy: 100 cm in 2 D | Reliability: 99. 9% Problem Management of the workflow in tram and bus depots is an important issue today. Knowing, if a vehicle enters or leaves a depot as well as the position of the each vehicle inside the depots is fundamental for correct dispatching, maintenance planning and invoicing. The Ubisense Solution VAB Depot Management System Ubisense Location Platform Each of the 40 trams and 135 buses of Je. Nah is tagged allowing the Ubisense platform to determine time stamps of incoming and outgoing vehicles and an exact bay, lane, and position of each vehicle, as soon as it is parked in- or outdoors in one of the depots. The online-interface to the Depot Management System of Verkehrsautomatisierung Berlin (VAB) enables the dispatchers to take better decisions and operate more efficiently. Results Correct, fast and reliable dispatching, correct invoicing of the work in a depot (maintenance, cleaning and preparation for the daily use) 14 Bus and Tram Tracking and Identification Case Study © by Ubisense 2009

ustomer Reference C Manufacturing Process & Energy Public Transport Logistics Agriculture Metro Transit Bus Depots Minneapolis, USA Military Events & Entertainment Other (Transit Yard Management) Installed area: xxx m² over 5 garages | Sensors: 450 | Accuracy: 100 cm in 2 D | Reliability: 99. 9% Problem Buses were being manually located and their location input into the Scheduling and Dispatching System using a paper mark-up sheet which was never up to date. Enterprise Intranet The Ubisense Solution Ubisense Transit Yard Manager Each bus of the 1000 buses of Metro Transit is tagged allowing the Ubisense platform to determine an exact bay, lane, and position of each bus, as soon as it is parked inside the garage and in some outdoor areas. Dispatchers have real time visualization of vehicles for assignment. Results Elimination of need for dedicated search personnel in each of the five Metro Transit garages. Faster and more reliable information about bus location Assistance in determining bus departure and arrival times and time spent in maintenance 15 Bus Tracking and Identification Case Study © by Ubisense 2009

Manufacturing Process & Energy Public Transport Logistics Agriculture Military Events & Entertainment Other www. ubisense. net 16 Case Study © by Ubisense 2009