OnSight delivers real-time tracking solution for NZ Steel

The Project

Digital Lean is a programme run by Callaghan Innovation, the first Lean programme focused on driving efficiencies around processes with people. Digital Lean is around driving efficiency in the manufacturing process and utilising Industry 4.0 concepts.
Beca and NZ Steel partnered up to run one of 8 Digital Lean pilot programmes in 2020. NZ Steel identified a need for a more streamlined tracking system within their COLORSTEEL® production site at Glenbrook. Two technologies were identified as possible solutions for tracking steel coils: RFID and Bluetooth Low Energy (BLE).
Onsight’s role in this project was to deliver a pilot solution using Bluetooth Low Energy (BLE); this was achieved using OnSight’s Core and Command applications.

The Results

BLE performed better than expected in an environment where there is a lot of metal that could get in the way of radio signals. Our Gateways could track beacons up to a 90m radius in this environment and for NZ Steel, it meant that a truck loaded with steel coils could be tracked as soon as it entered a zone.
BLE automatically tracks coils in range and without the need for worker input. The benefits were evident, even when comparing to more established technologies (Bar codes and RFID) and current processes, where each coil needed individual validation by a member of staff.

After coils are prepared they each receive a unique Bluetooth Low Energy beacon (ID) during the labeling process

The coils are stacked in storage ready to be loaded on to a truck ready for the Auckland Distribution site.

Truck and coils then leave the Loading Bay and Site [A] compound.

Truck and coils arrive at the Auckland Distribution site.

Truck and coils arrive to Storage [A] where coils will be unloaded, ready for further distribution.

Every coil of steel was tracked and these movements could be monitored down to the second in the tracking portal

OnSight’s experience and software platform made our experimentation with new hardware a breeze. Enterprise IT infrastructure can be challenging to deal with and they handled it amazingly well.

JEREMY SMITH

NEW ZEALAND STEEL – PRODUCT
DEVELOPMENT & INNOVATION