Rfid software computer associate

An automated truck tracking and loading system being rolled-out by the Conco Companies of Springfield, Mo., will provide the crushed stone operation with a key marketing tool, as customers will be able to get in and out of the yard quicker than what the competition can offer.

Future promotional pieces will highlight the value of Conco's speedier service and increased loading efficiency.

"They will want to come to our quarry because they will spend less time here," says Chris Upp, associate operations manager for Conco's Willard Quarry. "Most of the customer drivers who come in are getting paid on a per-ton basis," he explains, and faster turnaround times create a win-win situation for both quarry and customer.

When totally implemented, the security and production capabilities of the system will allow customer access on a 24hour basis.

Utilizing RFID--radio frequency identification technology--the YardTrack system from Emergent Technology of Springfield and Axcess International Inc. of Dallas is being implemented in stages at Conco.

"Eventually we want to have a fully automated loadout system," Upp reports. "Automated loadout is going to be big [within the stone industry], and we're planning for it now."

Conco executives were especially intrigued with the automation efforts being enthusiastically embraced by Rinker Materials Corp. and other operations. "We've been to the larger quarries that use RF in trucks and rail cars," Upp notes. Industry trade shows were another avenue of investigation before choosing the YardTrack application.

"We're looking at a 25 percent to 50 percent increase in throughput [at Conco]," says Jim Mohan, Emergent's CEO.

Tagging up

With the Axcess ActiveTag RFID system, a battery-powered (or "active") wireless tag is affixed to each truck coming in the gate, enabling the vehicle to be identified and tracked throughout the quarry as part of Emergent's supply chain management application.

When a customer initially signs up, the pertinent account information is programmed into the tag and the quarry's computer database.

Each tag transmits a signal to palm-sized receivers located at "control points" at the entrance and exit of the yard, and at the inbound and outbound weight scales. At each point, the work order information is electronically relayed to the driver and quarry crews.

The system records load time and weight, and then uploads the transaction information into Emergent's YardTrack software.

"Hands-free RFID automation provides the quarry operator with a real-time view of performance and productivity," says Ben Donohue, Axcess' vice president of business development.

"Using an automated approach to identify the truck and relay pertinent information to the driver and the quarry saves valuable time," Mohan says. "Moreover, productivity is increased with more frequent loads, while driver safety is improved. The ActiveTag technology significantly increases the amount of return for each vehicle."

The system is flexible enough to be rolled-out in manageable increments, says Upp, praising the adaptability and cost-effectiveness of the components. Additions will be made as the technology is blended into existing quarry operation procedures.

"We designed our products to make it easy for the customer to reap the benefits of RFID technology without the long and costly integration process," Donohue points out.

Runs itself

Upp is excited over the prospect of a fully automated quarry. For off-hours orders, drivers will ultimately be able to access the secure site and be directed by overhead lighted message boards to the proper loading area containing the desired material. "It will tell them to go to Bin 7," Upp says. "The truck will tare-out, the ticket will be printed and no one will have to be at the quarry." The system will manage and record the entire transaction.

Also, in-cab instructional displays will be installed in Conco's front-end loaders, providing details about the order being processed.

"[Currently], the loader operator will want to stay in the shade [away from the gate] and will not see a truck come in," Upp explains.

Initially, the system will instantly print job tickets as tagged trucks enter the yard. "They can pick it up and keep moving," Upp explains. Until the message boards are in place "we'll still have a speaker system set up."

Each year the operation produces 1.5 million tons of material from 1,000 acres. "We have lots of fines," says Upp, noting that Conco has multiple varieties of available rock products covering asphalt, concrete and a host of other applications.

Tagging the vehicles and automating yard operations is expected to have a strong impact on both production and sales. "It will give us a marketing tool," says Upp. "Trucks spend less time in our quarry."

Challenge

Modify loadout process for efficiency and cost savings.

Solution

Radio frequency identification technology.

Tip

Automated loadout allows for 24-hour customer access.