VELUX Commercial

Background

Global Leader and Innovator of Windows and Skylights

VELUX Commercial is a new division under the VELUX brand, based in Denmark, producing roof glazing solutions to provide daylight and fresh air through the roof. VELUX Modular Skylights manufactured in Ostbrirk, Denmark, can be combined in a number of rooflight configurations, creating perfect solutions for a wide variety of building types: narrow corridors, internal courts, studios, large circulation spaces, as well as private houses.

Goals

Enabling Continuous Improvement

VELUX Modular Skylights production went through extensive transformation of production processes, from manufacturing by hand into semi-automatic and fully-automatic processes. Digital Twin is enabling the transformation of physical world into a digital one, where:

• possible scenarios and ideas are tested to prove their benefits;
• production on wheels generates endless amount of data, which are transformed into valuable information for relevant decision-making;
• daily operational management is supported by real time information;
• production setup creates an ergonomically suitable and safer environment for the employees;
• virtual trainings for operators support safety, quality, and productivity;
• automatic data collection, real time monitoring and analytics create full image of the factory environment based on the facts;
• trends and analytic tools are the base for the future improvement of the whole system.

Challenges

A Digital Twin Integrating Multiple Systems

To support the current and future use cases, the system needs to collect data from multiple sources, such AGVs, operators, forklifts, machines. Then those data are transferred and processed into understandable, transparent and valuable information which are presented in 3D through various applications of Digital Twin of the real-life factory.

Solution

Real-time Digitalization of Movement Across Two Halls

To digitize movement, 12 UWB direct anchors are used, covering two production halls, each of 1,152 m². There are 40 personal tags, 17 tags on AGVs and 2 forklifts providing real-time location of people and machines operating within the facility. The real-time location data is integrated with production, Track & Trace and Plant Simulation, and the whole system is orchestrated via Ella platform.

Results

Boosting Efficiency Through Human-Machine Collaboration

Knowing in real time knowledge about status and position of 2 out of 4 production elements, Man and Machine, unlocks multiple use cases, along with the following benefits:

• Fully automated ergonomic adjustment of the AGVs

AGVs at VELUX Commercial have a gripper that holds and transports window frames across the halls. Once one of them reaches the workstation, its height is automatically adjusted to fit the height of the currently present worker or machine to provide the best ergonomic experience.

AGV that serves also as workbench, holding and moving the window.

• Workstation monitoring and management

Every workstation is monitored and checked for an appropriate number of operators, their right skillset level for the job and the maximum time they can work. If an AGV arrives at a workstation and waits for a particular time for a worker to appear in its proximity, it automatically calls the worker – this information is shown on monitors in the hall as well as in the application running on a PC. Similarly, if a person with an appropriate skillset is missing or a production step takes longer than usual, an additional support worker with the right skillset is called.

Hall monitor with real time data for Production Managers.

Workstation monitor with real time data about particular work zone.

• Total Productive Maintenance (TPM) with navigation for operators

TPM application within Ella platform creates environment where all information related to machines can be stored and easily accessible – standards for daily and long-term TPM activities, logbooks, location of machines, skill matrix of TPM contributors, reports. TPM application features a list of tasks, supported by description and pictures, that need to be performed on machines, how long they should take and who has been assigned to tasks.

After execution of TPM tasks, reports are created with comparison of plans and reality, e.g. if the task was executed – proven by localization of assigned operator, what materials and lubricants were used, time needed, issues identified.

Total Productive Maintenance (TPM) with navigation for operators.

• RTLS enhanced virtual reality trainings

The Digital Twin of the factory enables virtual-reality training in which the trainees do the training in the real-life and real-time reproduction of the actual environment. The training, in POV (Point Of View) camera mode, shows an AGV approaching a workstation and the monitor shows them the next operational steps they can practice during the training.

POV camera mode of virtual training.

• Advanced tools for visualizing complex statistical data

A spaghetti diagram gives a visual representation using a continuous flow line tracing the path of employees and machines (AGVs) within the facility. As a process analysis tool, the continuous flow line enables process teams to identify redundancies in the workflow and opportunities to expedite process flow.

Additionally, a heatmap shows traffic density withing the hall to help managers understand the concentrations of labor over time. The heatmap provides a powerful visual image of where efficiency opportunities may exist within a hall operation.

Spaghetti analysis.

Heatmap analysis.

• Parametric simulation model

The data from SAP, TaT and RTLS is combined within the Plant Simulation, allowing the identification of the constraints and bottlenecks that affect the efficiency of the production process, the definition of the capacity of the production and logistics resources, and the simulation and planning of production on a daily basis. It helps production managers to find the best efficiency variant that exactly meets customer demand.

Parametrization of production simulation.

• Single Source of Truth of Real-Time KPI Production Dashboard

Plant and production managers leverage the real-time data provided by the production dashboard for planning, monitoring, and optimizing the production process. The dashboard shows the current and historical production data and allows quick overview.

Admin Dashboard for Production Managers.

Key criteria for choosing Sewio

Reasons for Choosing Sewio RTLS

• 30 cm accuracy which allows the full flexibility and variability of virtual zones without any changes of infrastructure
• The ability to easily set an unlimited number of virtual zones that can be updated with a single click at any time in the future to adapt to any updates of processes
• Bi-directional seamless third-party integration with a fully-documented Open API
• Proven successful IOT projects using methodology and technology, backed up by unrivalled 10+ years of UWB expertise
• Multi-level support based on SLAs from the people who built the product
• The ability to scale the system easily and quickly to track more objects and expand the system to more halls