BLG LOGISTICS: The invisible becomes visible

The latest MotionMiners project takes Kolja Dittmann (Senior Business Improvement Manager) and Thomas Nell (Senior Process Improvement Manager) from BLG to the trimodal car terminal in Hamburg. Around 150,000 vehicles are handled there every year, including various value-added services for end customers. The two Improvement Managers have the easy-to-transport measurement equipment in a suitcase. It comprises 8 measurement sets (24 portable sensors) and 200 beacons (to localize measurement data via Bluetooth). Dittmann outlines the project goal as follows: “We want to achieve transparency about space efficiency, capacity utilization and the ergonomic situation of employees. ”

Real data for high credibility

It only takes two weeks to measure movement data. During this period, eight volunteers wear three sensors each day. Two are attached to the wrists with sweatbands, one to the belt. The easy-to-install Bluetooth beacons ensure safe positioning. Transfer inspection, tire conversion and vehicle preparation are measured. With manageable costs for the location. Nell summarizes the feedback from operations: “Employees are not affected and influenced by wearing sensors in their day-to-day business. Natural integration into everyday life creates valid process data for the measured processes. ”

Basis for quick decisions

At the end of the shift, the sensors are loaded into the docking station and the data is transferred to the analysis dashboard. Over 14 days, around 600 anonymized data hours add up. The subsequent evaluation in the MotionMiners PROCESS INTELLIGENCE software (MPI for short) reveals considerable optimization potential — from the areas used, over long distances to ergonomics in tire handling. It is easy to reach a consensus for the measures derived from this. “The real data ensures a high level of credibility vis-à-vis stakeholders and operational process specialists who work in the processes on a daily basis,” is Dittmann's experience.

The package of measures

It has already been decided that the handover inspection, tire conversion and vehicle preparation, which have so far taken place in two halls, will be bundled under one roof. As a result, an entire hall is saved. “We will significantly reduce electricity and heating costs, which will contribute to our sustainability and cost targets,” Dittmann calculates. In the area of ergonomics, the burden on tire handling employees is to be reduced. “Here we are in the test phase with various exoskeletons, which we will put into regular operation if the evaluation is positive,” adds Dittmann.

As part of the project, the BLG team also equipped objects with motion sensors to test their ergonomic relevance. Specifically, it concerns stools that employees use to prepare vehicles. The analysis allows Dittmann to quantify the benefits: “Without the stool tool, the bent posture is 50 percent higher. ”

Employees and works council on board

For employee acceptance, it is essential not only that measurement is carried out, but that improvements result from this. Another aspect is integration right from the start. At information events, employees will learn about technology, measurement and analysis goals, and the question “What happens with my data? “enlightened. In accordance with the General Data Protection Regulation (GDPR), data protection is paramount. The works council is involved in MotionMiners projects in parallel. “From his point of view, it is of paramount importance that the personal rights of employees are always respected and that neither data nor analyses can be broken down to individual people,” explains Nell.

3 stages: test phase, pilot phase, license purchase

BLG started working with MotionMiners in 2020 as part of a 100-day innovation project in Bremen. This format gave participants the opportunity to try out the application for 100 days. “We then carried out two pilot projects in Bremen and Sindelfingen. The results convinced us to purchase the equipment as a license,” concludes Nell. He considers it easy to get started with the tools. The training required for analysts is around one day, for employees it is significantly less.

First in-house project in contract logistics

In addition to the project at the car terminal in Hamburg, BLG has so far carried out another project in the area of contract logistics in Bremen. This case involved preparatory handling activities for overseas container shipments, in which automotive parts were repacked from reusable to one-way load carriers. The measurements provided evidence that the supply of packing areas was no longer optimal due to changing conditions and that employees worked a lot in a stooped position. The improvement measures include a test phase with exoskeletons and logistical optimizations.

Institutionalization of the measurement case

Following the successful individual projects in the areas of contract logistics and automotive handling, BLG wants to institutionalize the use of MotionMiners' automated and anonymized process analysis at other domestic automotive terminals. “When it comes to comparable topics, it's worth taking a closer look at the processes there,” concludes Nell. The experienced process analyst also still sees great potential in contract logistics.

Planned: Operational data matching and vehicle loggers

BLG plans to integrate further MotionMiners features in the future. To better evaluate fleet management, the “so-called fleet package, consisting of the vehicle logger and the sensor and smart beacon, is to be used. With this sensor set, vehicle movements, fork operating times/lift heights and empty/full runs can be logged. When evaluating, BLG analysts also want to use the function of operating data matching. Here, the movement data collected using motion mining technology and proprietary data from TMS, WMS and ERP systems are combined in the MotionMiners analysis platform.

“This would bring us to a new level of quality in analysis,” says Dittmann happily and explains, “with MotionMiners, we have already made the blind processes between scan points visible. By including our status information or order data, we can further reduce the processes.” With this deeper analysis, the following specific questions could be answered, for example: Which vehicles are particularly complex to prepare? Which packages are very time-consuming to handle?

Key figures for the new building

Cooperation with MotionMiners is characterized by competent, rapid support. Even though the analysts take on all steps on their own, they can rely on the support of the technology company in every phase of the project. For example, MotionMiners was present at the BLG car terminal in Hamburg at the start of the project to optimally prepare the data measurement. On the 324,000 m2 site with 10,000 parking spaces, the results of the MotionMiners analyses are also incorporated into a strategic project. The course is currently being set for the construction of a new multifunctional hall there. This is intended to combine all services there, such as painting, preparation, workshop and mechanics, under one roof. “Walking and driving routes, space efficiency and ergonomic working methods are optimized based on the key figures determined with MotionMiners,” explains Dittmann.

BLG car terminal in Hamburg

BLG LOGISTICS' Hamburg trimodal car terminal is located on the Kattwyk Peninsula on the Elbe. On a total area of 324,000 m² and a parking space for 10,000 vehicles, around 150,000 units are handled and prepared for end customers every year. In addition to automotive manufacturers, customers from the areas of dealers, large fleets, remarketing, car rental companies and auction houses are served. Services include preparation, handover inspection, tire retrofitting, painting, wrapping and other workshop and mechanical activities.

About MotionMiners

Sascha Kaczmarek, Dr.-Ing. Sascha Feldhorst and Dr.-Ing. René Grzeszick founded MotionMiners GmbH together in October 2017. The company now employs around 70 people at its location in the Dortmund Technology Center. The company wants to provide the world's most flexible and comprehensive analysis toolbox for human activities. This is intended to continuously improve the daily work of analysts and the ergonomic working conditions of operational staff within the investigated processes.

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Press contacts

MotionMiners GmbH

Paula Brandt

+49 (0) 176 6016 4784

paula.brandt@motionminers.com

Lütpress

Stephanie Lützen

+49 (0) 160 8412104

luetzen@luetpress.de

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