Integrated solutions to deliver Security, improve operational efficiency and reduce accidents at the manufacturing industry

As one of the most commonly used tools in plant logistics’ activities, forklifts/AGVs are playing an increasingly important role in the manufacturing process. Once an accident occurs, it will cause production interruption and even casualties could be produced.

The best way to prevent accidents is to make sure that no one enters the working area of the forklift/AGV while it is working. With built-in Video Analytics, Bosch cameras can smartly differentiate between a person and a forklift/AGV, and instantly create an alarm if anyone steps into the forklift/AGV area when it is moving. Meanwhile, workers can actively be warned when forklifts/AGVs come too close. By adding specific script rules, cameras can intelligently know under what kind of circumstances they do not need to alarm, even with people around. For instance when the vehicle has to stop for unloading or a status check.

Of course, it is also necessary to raise the safety awareness of drivers. Cameras with built-in video analytics can define paths that forklifts/AGVs need to follow. Non-rule-obeying forklift drivers can be identified and asked to follow additional safety training. Based on the camera footage, accidents can be investigated and analyzed, with the improvement of routes and rules as a result.

The use of safety vests by people that work in potentially hazardous areas makes them easily visible, in order to prevent injuries and accidents. To manage safety protocol at the site and making sure that all of the employees are following the protocols on wearing safety vests, surveillance cameras can be used to enforce the safety rules. Using our cameras with built-in Video Analytics, it is possible to differentiate whether a person is wearing a safety vest or not. If not, the verification done by the camera allows the Access Control System to give access only to workers wearing a safety vest. This way non-rule-obeying workers can be identified and receive additional safety training. In case of an audit, this solution can proof that the company is managing the safety protocol.

Manufacturing companies that operate in different countries or even continents, could benefit from a solution to control access rights for several sites in an efficient and transparent way. With the Access Engine of our Building Integration System (BIS), Bosch offers you a global access solution for multiple offices and manufacturing sites, in a centralized management system with one central database. This allows employees who visit different sites to easily enter the building with a standardized ID card, that can provide access to all sites. This way it saves the company time and money, because it is no longer needed to apply for a temporary access card each time, going through all the additional security procedures. Also, 3rd party software can be used to tailor specific solutions according to your wishes. The global presence of Bosch ensures that everywhere in the world you can get support for setting up your local sites. Furthermore, our solutions are perfectly scalable for future expansion of your business.

With the Internet of Things (IoT) and a customized integration between video analytics and warehouse management software it is possible to create a solution to detect inventory theft and track missing shipments.

Bosch cameras with Intelligent Video Analytics process image data in real time and detect suspicious activities using an algorithm. Using their built-inCamera Trainer, Bosch cameras can be taught to recognize objects in the warehouse such as forklifts and shipment items. Once the security system learns to identify these objects, it is ready to interface with the center’s logistics system.

The next step is to create a direct interface between the warehouse management system and BVMS – the video management system from Bosch. Creating the connection adds a new level of intelligence to the center’s video surveillance: the smart cameras now act as IoT sensors, that can identify products stored in the warehouse management system software. The system automatically cross-checks security incidents with scheduled tasks in the warehouse system. Thanks to this ‘smart’ automation, operators only receive an alarm when a worker enters an aisle without a task – and no alarm is triggered if the worker passes through without stopping.

From an operations perspective, this Industry 4.0 solution not only boosts security but also answers the center’s need to replace the time-consuming manual tracking process for misplaced items and shipments.

As an important part of modern production and logistics, a smooth conveyor belt transportation symbolizes the smooth operation of the entire production line and/or logistics transportation process. An accumulation of products on the conveyer belt means that somewhere in the production or logistics chain something goes wrong. If not handled in time, it may eventually lead to the interruption or even paralysis of the entire production line or logistics’ process. Bosch intelligent cameras with Camera Trainer can be trained to give an occupancy alarm if there are too many boxes, so that operators can be informed timely to check, ensuring not to distort production or logistics. Moreover, Bosch cameras can generate business intelligence with structured video data by monitoring the conveyer belt, which is helpful to optimize production and logistics.

Production plants have a great demand for raw materials, which are usually supplied by different vendors. Therefore, the IQC (incoming quality control) of these materials has always been tricky. When the quality control operator needs to check the materials by random samples, it is often very difficult for them to find out the target due to excessive incoming materials and chaotic piling up. A great deal of time and manpower are hence wasted.

Using their built-in Camera Trainer, Bosch cameras can quickly locate the incoming materials that need to be inspected amongst huge quantities of materials, by learning how to read different vendors’ tags. This greatly shortens the inspection time of the IQC operator and improves highly the efficiency for the production.

A smooth production is depending on the constant availability of assembly materials. When the materials are put on shelves or racks, operators constantly need to check whether the stock needs to be replenished. Relying on such an incidental inspection could lead to delayed replenishment or even supplies being out of stock. This leads to low production efficiency as well as valuable time of personnel being used.

Using their built-in Camera Trainer, Bosch cameras can inform you about the status of your supplies. They can for instance detect that material boxes on a shelve are empty and also they can be trained to know what is in each specific box. They can notify operators in time about the materials out of stock and which materials need to be replenished. Moreover, by connecting with BVMS - the video management system from Bosch -, the inventory can be vividly visualized in real time. This ‘virtual inventory’ can significantly reduce costs, shorten the replenishment lead time, and ensure a smooth production.

Production halls are environments with loud ambient noise, in which unclear announcements confuse workers or are simply not heard. In case of evacuation it is crucial that everybody knows what to do, so being able to offer a good distribution of sound, even in big spaces with high ceilings like production halls, is crucial. Next to this important element of safety, being able to listen to music while doing production work, significantly improves the working conditions of workers in many cases. Bosch has an extensive loudspeaker portfolio, with flexible Public Address (PA) solutions that can increase/decrease sound levels in environments with loud/low ambient noise, provide control over a small and very specific area or can also address the full production plant if necessary. Especially suitable for large areas and high-ceiling applications like production halls is the powerful Hemi-directional loudspeaker. Because of the exceptionally large area this loudspeaker can cover, only very few are needed in large halls, making it a very cost effective solution.