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The IoT Ecosystem

Source: DHL (2024)

Relevance to the Future of Logistics

Predictive Maintenance

Traditional asset maintenance methods, which rely on periodic inspections, may fail to identify abrasion and may overlook details that could lead to unforeseen expenses, reduced productivity, downtime, accidents, and equipment damage. Instead, data-collecting sensors can create insights about the condition and operations of all assets and software analytics can be employed to generate reports that highlight potential problems or risks of failure.

This explains why more and more companies are developing retrofit solutions to implement predictive maintenance, especially for older assets that are more susceptible to repair and failure. For example, DHL is using noise sensors for predictive maintenance of its sorters – these machines are the core component of successful automated sortation operations and, typically, maintenance is time intensive and not very effective. Instead, the noise of individual cells can be used to identify at an early stage whether maintenance is required. DHL developed an algorithm to analyze this cell-noise data and provides visualization and alerts on a DHL IoT platform. This predictive maintenance solution is cost effective, helps avoid outages, reduces unnecessary maintenance activities and overall effort, and enables the switch from calendar-based to event- and/or alert-based maintenance.

Asset Tracking

Between 10% and 40% of supply chain assets are lost globally through misplacement, theft, and breakage every year. Smartification of assets such as pallets, forklifts, and containers enables localization and tracking. For example, since 2019, DHL has equipped more than 500,000 roller cages with smart long-lifetime trackers from manufacturer Alps Alpine, providing transparency on asset usage and improving distribution to ensure there are always enough cages at every location.

Another example is the partnership between shipping company Hapag-Lloyd and IoT-technology provider Nexxiot to create the world’s largest connected fleet of smart containers. By the beginning of 2024, more than one million solar powered, cellular asset-tracking devices with a runtime of 6-10 years were installed in the shipper’s dry container fleet.

Real-time location system (RTLS) manufacturer Sewio provides a forklift tracking solution to equip vehicles with a tag that transmits a signal to ceiling-mounted anchors. The anchors send any signal to the RTLS server so each vehicle’s position can be calculated in real time, within 30 cm (11.8”) accuracy. The tag can be powered from the vehicle’s battery or by its own battery. Collected data also provides insights into metrics such as distance traveled, run time versus stop time, and overall equipment effectiveness.

Facility Monitoring

It is crucial to monitor environmental conditions within logistics facilities in order to prevent exposing goods to extremes of heat, cold, and excessive humidity – requirements that are especially relevant in the pharmaceutical, food, and technology industries. Companies also need to monitor and understand facility energy consumption to identify and quantify potential energy savings, improving the carbon footprint and lowering energy costs. Retrofitting warehouses and production facilities with sensors can help with these tasks, providing data for analysis and informed decision making.

Companies like Singapore-based BeeBryte can measure, predict, and even independently adjust energy consumption-related functions (such as heating, ventilation, and air conditioning) in smart production facilities, warehouses, and commercial buildings. By analyzing data from different sources (for example, sensor-based, warehouse activity information and external sources like weather and traffic) the system can automatically adjust to optimum levels.

Challenges

Challenge 1

The assimilation of formerly analog assets and systems into a corporate IT ecosystem and the increasing number of connected devices raise the risk of cyberattack.

Challenge 2

Integrating sensors from different suppliers requires a strong IT ecosystem and various application programming interfaces (APIs) to ensure all data is linked on one platform.

Challenge 3

The shift towards smart facilities, connected assets, and data-driven processes is expensive as well as time intensive.

Challenge 4

Growing data volumes due to the smartification of assets and systems means decision makers must learn to analyze this data and draw correct conclusions from it.

Challenge 5

Not every analog asset can be retrofitted with sensors and wireless technologies.

The assimilation of formerly analog assets and systems into a corporate IT ecosystem and the increasing number of connected devices raise the risk of cyberattack.
Integrating sensors from different suppliers requires a strong IT ecosystem and various application programming interfaces (APIs) to ensure all data is linked on one platform.
The shift towards smart facilities, connected assets, and data-driven processes is expensive as well as time intensive.
Growing data volumes due to the smartification of assets and systems means decision makers must learn to analyze this data and draw correct conclusions from it.
Not every analog asset can be retrofitted with sensors and wireless technologies.

Outlook

As sensor technology advances and the cost and size of sensors shrink, more and more smartification use cases are emerging. This means newly produced assets are increasingly smart from the outset and there are more and more opportunities to digitize analog assets by retrofitting them with sensors. With the general trend towards more transparency and data harvesting, the relevance of the smartification trend will continue to increase in the future.

This trend should be CAREFULLY monitored,with use cases in some applications that can already be addressed today.

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Sources

  1. Statista (2023): Number of connected devices worldwide in 2014 and 2028, by device
  2. Worldometer (2022): World Population Projections
  3. Forbes (2023): 2024 IoT And Smart Device Trends: What You Need To Know For The Future
  4. Hapag Lloyd (2024): One million dry container monitoring devices installed!