See the value that AeroScout WIP throughput solutions have brought to our industrial customers; increase scheduling accuracy, improve efficiency, and streamline production.

1. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
WIP
THROUGHPUT
CUSTOMER STORIES
1.

2. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
WIP THROUGHPUT CUSTOMERS
 Viracon
 Continental Tire
 Boeing
 John Deere
 Freescale Semiconductor
 Caterpillar
 Wrigley
 Komatsu
 Celanese
 Daimler
2.

3. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Continental, the leading global tire manufacturer
Where?
US and France
Why?
Long searches for assets increased cycle times, decreased
labour optimisation, and increased non-compliance. There
was also a high scrap rate.
 Reduce cycle times, improve labour optimisation, and increase compliance with production
schedules by reducing search times for assets
 Reduce high scrap rate, associated with lost carriers
Goals
 All carriers tracked in real-time using T2-EB tags on a Cisco Wi-Fi network
 Material handlers, truckers, and managers can search in real-time for components by ID,
tread number, material code, or according to date (FIFO inventory management)
 MobileView is displayed on the carrier tug
 Integrated with Continental’s MITS (Material Inventory Tracking System)
 Automated alerts, such as empty carriers requiring collection
 Reduced operator search times thanks to continuous real-time visibility across entire plant
 20% reduction of breaker component tire loss
 Increase in tire machine utilisation, ensuring increased production and higher overall
equipment efficiency (OEE)
 Reduction in scrap loss through FIFO component management
Solution overview
Outcomes
TYRE MANUFACTURING THROUGHPUT
3.

4. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Freescale, the multinational semiconductor company with
design, research and development, manufacturing, and sales
operations in more than 75 locations across 19 countries
Where?
Texas, USA
Why?
Lengthy manual searches were inefficient and reduced
production efficiency. Customer satisfaction was also
impacted due to delayed deliveries.
 Improve production throughput by increasing efficiency of labour use and reducing search
times
 Increase customer satisfaction through fewer production delays, enabling delivery times to
be met
Goals
 Tags were mounted on 4,000 wafer lots with exciters above the WIP tracks for rack level
accuracy
 Additional exciters used throughout the fab for WIP tracking
 MobileView integrated with the fab’s MES to ensure schedule compliance
 Requested carrier from MES sends a signal to MobileView activating a blinking LED on the
tag
 Freescale’s productivity improvement and throughput increased by 6.8%
 Average lot transaction time was reduced by 82%
 On-time deliveries improved by 13%
 Dispatch compliance improved by 8% (photo-lithography increased by 25%)
 Operator headcount could be reduced by 10%
 Dwell times and lost lot events were decreased
Solution overview
Outcomes
“The payback has exceeded our
expectation, 82% improvement
in retrieval time resulted in
increased throughput, and on-
time delivery was improved by
13%”
- Chris Magnella, Operations
Manager
LOT BOX TRACKING
4.

5. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Caterpillar, the designer and manufacturer of construction
and mining equipment, engines, turbines, and locomotives
Where?
US and UK
Why?
There was a lack of visibility of Caterpillar’s Front Loader
manufacturing line, and manually locating jobs reduced the
plant’s efficiency
 Give visibility into real-time production and individual department productivity
 Improve plant manufacturing efficiency
Goals
 T2-EB tags attached to the Loader chassis with tie wraps at the start of the production line,
staying attached until the end of the manufacturing process
 EX2000 and EX3210 exciters mounted along department entry and exit points throughout
manufacturing line
 MobileView displays real-time counts of Loaders in each department or stage
 Established MobileView alarms to monitor Loader dwell time in the department, configured
to >40 minutes
 System provides production management with continuous visibility of the Loader
manufacturing progress within each department
 Track and trace at department level continuously measures real-time performance against
the daily manufacturing goals
 Real-time notification is sent if daily manufacturing goals are in jeopardy due to department
dwell time
 Production data is used to analyse bottlenecks to streamline process and improve efficiency
Solution overview
Outcomes
HEAVY EQUIPMENT MANUFACTURING
5.

6. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
William Wrigley Jr. Company, the food processing company
and chewing gum manufacturer with operations in over 40
nations
Where?
Multiple worldwide locations
Why?
Complex routings and product processing needed to be
simplified, and hundreds of similar pallets requiring this
complicated processing made operations less efficient
 Enable quick identification of correct pallet amongst multiple similar pallets
 Support simplification of processing throughout network of sophisticated, highly-regulated
facilities around the globe
Goals
 Tags mounted on 400 pallets
 Leveraging existing Cisco LWAPP access points deployed in factory
 Exciters located at each loading and unloading station to provide immediate arrival
information
 Integrated with Wrigley’s production software and provides seamless location accuracy
 Temperature monitoring tags placed on each of the pallets in cooling tunnels
 Wrigley experienced a reduction in the quantity of scrap material
 Manufacturing processing and product quality improved
 Incorrect processing is avoided
 Better control of manufacturing and packaging processes
Solution overview
Outcomes
MANUFACTURING QUALITY
6.

7. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Komatsu, Japan’s largest manufacturer of construction and
mining equipment, with 45 factories
Where?
The Osaka plant in Japan, which is responsible for designing
and building all Komatsu products
Why?
Manual searches for vehicles were time-consuming and
caused delays, which harmed customer satisfaction
 Improve customer satisfaction
 Improve search times
Goals
 T6 GPS tags placed on units at the beginning of production
 Leveraging the existing Cisco Wi-Fi network, choke point exciters, and GPS satellites to
track units both indoor and outdoors
 MobileView software integrated with Komatsu MES software to optimise operations
 Komatsu experienced reduced lead time in 7 areas: Transport, Motion, Waiting, Over-
producing, Over-processing, and Defects
 Productivity increased as they cannot reduce ‘wastes’ unless it is visualised
 Fixture search times was all but eliminated
 Customer satisfaction improved due to real-time data and ease of response to queries from
field
Solution overview
Outcomes
HEAVY MANUFACTURING THROUGHPUT
7.

8. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Celanese, the global technology and specialty materials
company
Where?
Mexico
Why?
The company was experiencing bottlenecks with trucks or
drivers not where they were needed
 Improve port throughout
 Ensure the right truck and the right driver arrived at the right location at the right time
Goals
 Partner GDSI implemented a mixed solution that included both active and passive RFID
 Cisco wireless network was installed throughput the plant
 AeroScout technology tags were mounted on mobile, high-value assets whilst passive RFID
tags were used for low-value, less mobile assets
 MobileView software used to track both active and passive tagged assets
 Celanese experienced significant throughput improvement through the facility
 Increase traceability of parts and components
Solution overview
Outcomes
DISTRIBUTION THROUGHPUT
8.

9. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Daimler, the German international automotive corporation
Where?
Engine remanufacturing facility in Mannheim, Germany
Why?
Engine remanufacturing progress was difficult to determine,
and covered 5 buildings on a very large site. The facility
takes special expedited orders for customer satisfaction, so
misplacing engines had a negative impact
 Avoid misplacing engines during remanufacturing process by tracking engines across whole
site
 Improve customer satisfaction
Goals
 Tags mounted to engine carrier frames
 Tags are married to a tracking system at process start, via a barcode
 Steps and areas marked with zones and exciters
 Engine location can be discovered via either the shop floor system or MobileView
 Misplaced engines eliminated, increasing on-time deliveries and improving customer
satisfaction
 Customer retention improved due to more accurate order updates
 Throughput increased by eliminating unnecessary movement
 Cycle times predictability and consistency dramatically improved scheduling and customer
service
Solution overview
Outcomes
ENGINE REPAIR AND OVERHAUL
9.

10. SMART, SAFE, AND CONNECTED.
Thank you.
If you would like further information,
please get in touch via info@extronics.com
or call us on +44 845 277 5000