IoT Enabled Smart Warehouse Solution

IoT enabled Smart Warehouse Solution 2017 Cognizant 2017 Cognizant

AgendaBusiness ChallengeIoT Smart WM SolutionTechnical SolutionBenefits 2014 Cognizant

Traditional Inventory Management (Business Challenge)Inventory data is received &recorded manually and keyedinto ERPERP SystemUser Queries Inventory Data FromThe ERP SystemInaccurate Inventory Data is displayed onERP1WarehouseIncoming Inventory Pick2Measurement Errors ininventory data gatheredfrom WarehouseIn-Transit inventory datacannot be gathered in realtimeWarehouse1.2.3Delay in gatheringdispatchedinventory data fromManual inventoryWarehouseCollection42Inventory 2014 In-Transit Inventory1Pack3.4.5.6.7.Longer turnaround time for the picking and packingprocessMismatch between inventory data in ERP and actualinventory in warehouseWasted warehouse space due to lack of oversightinto space allocationManual Effort and Labor managementReal Time data gathering for shipment is not trackedWrong order/shipment/delay will badly affectbusinessLack of end-to-end visibility on inventory

Use casesUse case for complete IoT enabled Warehouse solution like Space Allocation Optimization (3) Automatic navigation to the inventory storage (4) Inventory management and control (1,2 and 5) IoT Enabled Smart Shipping (5) Monitor Fork Lift Truck Usage and Health4 2014 Cognizant

IoT Enabled Inventory ManagementIoT Cloud gathers inventory datafrom goods receiving bayIoT Cloud AggregatesInventory Data121.4Inter-warehouseIn-Transit InventoryIoT Cloudgathers dispatchedinventory data fromWarehouse3InventoryClass A 2014Class A Inventoryis Cognizantcontinuallymonitored by Drone and AGVERP SystemIoT Cloudgathers In-Transitinventory data from allwarehousesIoT Cloudgathers warehouseinventory data fromWarehouseClass B and CVisual DashboardNet Inventory Data isdisplayed as a visualDashboardNet Inventory DataWarehouseIncoming InventoryWarehouseUser Queries Inventory DataFrom The ERP SystemThe ERP System QueriesIoT Cloud for theInventory dataWarehouseOutgoing Inventory12.3.4.5.Real time data received from sensors/beacons ensure that actualinventory levels are measured.Real-time updates on inventory count, alerts for mismatch betweeninventory data in ERP and actual inventory in warehouseRestocking process becomes more efficient and stock out losses areavoidedAutomated Navigation within WarehouseEnd-to-End visibility on inventory

IoT ArchitectureWarehouse(s)REST APISAG Device Integration PlatformData IngestionDevice ConnectorsEdge AnalyticsSAG Analytics PlatformEvent StreamingEvent ProcessingEvent StoreEvent AnalyticsIOT PlatformSAG Application Integration PlatformService Bus Application ConnectorsAPIEWM 2014 CognizantAPITMSAPIERPApplication(s)

Solution DetailsDerive Inventory count in each rackby count of beacon stickersdetectedMobile App/Agent to publishInventory Update Events to DIPDevice Metadata, Model, Hierarchy,Measurements, EventsDashboards, Notifications, AlertsBeacon Sticker(s)SAG DeviceIntegration PlatformSAG AnalyticsPlatformGateway Device(Mobile)EWMIOT PlatformSAG IntegrationPlatformTMSWarehouse map with item locations pinned(Act as Indoor Positioning System[IPS])ERPGet Work Order and Pick ListDetailsMobile DeviceForklift OperatorFork Lift Scanner to detect itemspicked via beacon sticker identifiers 2014 CognizantIntegrate with Enterprise ERP andWarehouse systemsGet Indoor Location Coordinatesassigned to each Items/productsBLE EventsData Flow

Warehouse and Devices - PerspectiveEstimote Location/Proximity Beacons – Attached torack/bay to identify LocationEstimote Beacon Stickers - Attached to Items/palletsto identify inventory in each rackTruckLoading BayBeacon Tracking(Fixed) – To track inventory in eachrack (Using Raspberry PI kind device as gateway)Beacon Tracking(Mobile) – While Item Loading onForklift (Using Mobile/Tab as gateway)Beacon Tracking (Fixed) – To validate item loadingon truck (Using Raspberry PI kind device as gateway) ForkliftOperatorWarehouse map with item locations pinned 2014 CognizantBLE integration with all beaconsLocation Beacons coordinates mapped to warehouse loadingbay/item locationsBeacons Stickers with unique id tagged to each ItemOperator forklifts equipped with beacon tracking device to identify– Items and locationsOperator forklifts equipped navigation device to display navigationroute to Item/Loading bay

9 2017 Cognizant

Mashzone NextGen Real Time DashboardPick Item Locations Pinned 2017 CognizantReal TimeInventory StatusReal TimeInventory Count

DIP Snapshot – Work Order Events 2017 Cognizant

Solution Components 2014 CognizantSoftware AG Apama and DIP ConnectorSoftware AG Device Integration PlatformSoftware AG MashZone NextgenTerracotta In-Memory FabricUniversal MessagingSoftware AG -webMethods Integration Server

Our SolutionHow the real time, automatic stock / inventory can take placeIt is possible to achieve this in 3 ways.1.2.3.Using Automated guided vehicle fitted with device to scan/read the itemsUsing drones fitted with device to scan and read the itemsUsing Mobile readers to scan / read the items and move around the warehouse to capture the informationBased on the warehouse floor design, budget, type of industry and materials , suitable option or combination of options possible to choose 2014 Cognizant

IoT in Inventory Management Using Bluetooth Low Energy (BLE)ERP SystemReal Time Inventory Data is available touser over his smartphoneThe Aggregated Data is processedby ERP to verify inventoryFixed ReceiverWIP/FG InventoryMobile ReceiverBLE Beacons Transmit InventoryData to Fixed/Mobile ReceiversIn-transit FG InventoryBLEBeaconsTransmitters areattached to theinventory/pallets14 2014 Cognizant

Business ChallengeThis presentation focuses on use case of Smart Inventory and Shipping aspects of Warehouse ManagementSome of the business challenges with respect to inventory management Lack of end-to-end visibility on inventoryMismatch between inventory data in ERP and actual inventory in warehouseDaily stock taking is virtually impossibleErrors in order processing resulting in missing itemsWasted warehouse space due to lack of oversight into space allocationLonger turnaround time for the picking and packing processInefficient allocation of resources and equipment due to non-standardized processes 2014 Cognizant

IOT enabled Smart Warehouse – Virtual warehouse - Overview21Inbound InventoryAutomatic navigation & SpaceOptimization IoT identifies the right locationfor the inventory and assignsthe available physical storagelocation. IoT updates Virtual Warehouseand ERP3WAREHOUSEPROCESSRECEIVINGUnload VehicleInspect for damageRecord the inventoryPut-awayIdentify InventoryIdentify Storage LocationMove ProductsUpdate Records Sensors at the receiving conveyorcapture the inbound inventory dataand feed the same into IoT Cloud.Space Optimization UseCase IoT very frequently tracks Class Ainventory with drones and AGVs. Class Band C inventory are tracked with BarCode/QR Code scanners on Weekly andMonthly basis respectively. IoT sensors record physical spaceutilization4StorageStock LocationSpace UtilizationMaterial FlowInformation Flow6Inventory management IoT verifies accuracy of theorder before packing IoT tags the packages withcorrect delivery information IoT identifies the right carriervehicle for each order IoT tracks the movement ofshipments using GPS andupdates the data into trackingdatabase 2014 Cognizant5Shipping PreparationPackingLabelingStacking7Smart SHIPPINGSchedule CarrierLoad VehicleBill of LoadingRecord UpdateOrder PickingOrder InformationNavigation GuidanceOrder PickingAutomatic navigation IoT looks up Virtual Warehouse forordered inventory and provides thelabor/AGV with navigation data. IoT guides the labor/AGV to pickright inventory8Outbound Shipments

Solution BenefitsBenefits of IoT enabled Inventory Management End-to-End visibility on inventory Real-time updates on inventory count Real-time alerts for mismatch between inventory data in ERP and actual inventory in warehouse Real time data received from sensors/beacons ensure that actual inventory levels are measured Restocking process becomes more efficient and stock out losses are avoided 2014 Cognizant

Inventory data Warehouse Outgoing Inventory IoT Cloud gathers warehouse inventory data from Warehouse IoT Cloud gathers dispatched inventory data from Warehouse . Based on the warehouse floor design, budget, type of industry and materials , suitable option or combination of options possible to choose.