{"id":17896,"date":"2016-11-30T18:16:27","date_gmt":"2016-11-30T15:16:27","guid":{"rendered":"http:\/\/www.altoros.com\/blog\/?p=17896"},"modified":"2019-09-23T14:51:18","modified_gmt":"2019-09-23T11:51:18","slug":"smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags","status":"publish","type":"post","link":"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/","title":{"rendered":"Smart Locomotive Manufacturing: Material Tracking with Predix and RFID Tags"},"content":{"rendered":"<p>The agenda of a recent <a href=\"https:\/\/www.meetup.com\/GE-Predix-Detroit-Industrial-Internet\/events\/229689362\/\" target=\"_blank\" rel=\"noopener noreferrer\">Predix meetup<\/a> in Detroit was focused on IIoT solutions for coordinating supply chains in manufacturing. <a href=\"https:\/\/www.linkedin.com\/in\/ashokmadhuranath\" target=\"_blank\" rel=\"noopener noreferrer\">Ashok Madhuranath<\/a>, enterprise architect and senior technologist at GE Transportation, spoke about how the Industrial Internet and real-time data can help to identify operational bottlenecks and improve legacy processes within a plant.<\/p>\n<p>&nbsp;<\/p>\n<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_82_2 counter-hierarchy ez-toc-counter ez-toc-transparent ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/#Why_automate\" >Why automate?<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/#Developing_an_IoT_solution_with_RFID_and_Predix\" >Developing an IoT solution with RFID and Predix<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/#Results_and_lessons_learned\" >Results and lessons learned<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/#Want_details_Watch_the_video\" >Want details? Watch the video!<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/#Related_reading\" >Related reading<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/#About_the_expert\" >About the expert<\/a><\/li><\/ul><\/nav><\/div>\n<h3><span class=\"ez-toc-section\" id=\"Why_automate\"><\/span>Why automate?<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>GE has more than a century-long history of serving the railroad industry, delivering freight and passenger locomotives. The newest generation of GE locomotives\u2014the <a href=\"https:\/\/www.wabteccorp.com\/business-units\/ge-transportation\" target=\"_blank\" rel=\"noopener noreferrer\">Evolution Series<\/a>\u2014was introduced in 2005. It has been upgraded since then to comply with more stringent <a href=\"https:\/\/www.epa.gov\/emission-standards-reference-guide\" target=\"_blank\" rel=\"noopener noreferrer\">emission standards<\/a> adopted by the U.S. Environmental Protection Agency and to increase fuel efficiency.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-transportation-texas.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-transportation-texas.png\" alt=\"ge-predix-transportation-texas\" width=\"640\" class=\"aligncenter size-full wp-image-17942\" \/><\/a><\/p>\n<p>The GE\u2019s plant in Fort Worth manufactures more than 500 Evolution Series locomotives a year, with each locomotive comprising thousands of parts. A huge number of the materials sourced from around the world is continuously being transferred from the company\u2019s warehouse to its 10 assembly lines.<\/p>\n<blockquote><p><em>&#8220;There&#8217;s a constant need for replenishing and making sure the parts are available where they need to be on the assembly lines.&#8221; \u2014Ashok Madhuranath, GE<\/em><\/p><\/blockquote>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-cart-tracking.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-cart-tracking.png\" alt=\"ge-predix-cart-tracking\" width=\"640\" class=\"aligncenter size-full wp-image-17936\" \/><\/a><\/p>\n<p>Carts are the basic units of the delivery process at Fort Worth that play a crucial role in moving parts between the warehouse and the plant. Made to carry specific materials, the carts are labeled with an identification number, order number, and destination.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-rfid-tracking.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-rfid-tracking.png\" alt=\"ge-predix-rfid-tracking\" width=\"640\" class=\"aligncenter size-full wp-image-17939\" \/><\/a><\/p>\n<p>Before the new tracking system was designed, the information about the carts and their location had been handled using multiple whiteboards, spreadsheets, and manual lists for cart configuration and status checks. The cart flow was lacking real-time visibility; four dedicated employees were searching for lost carts with supplies.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-plant-tracking.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-plant-tracking.png\" alt=\"ge-predix-plant-tracking\" width=\"640\" class=\"aligncenter size-full wp-image-17938\" \/><\/a><\/p>\n<p>&nbsp;<\/p>\n<h3><span class=\"ez-toc-section\" id=\"Developing_an_IoT_solution_with_RFID_and_Predix\"><\/span>Developing an IoT solution with RFID and Predix<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>Aiming at operational and planning efficiency, the GE team implemented an <a href=\"https:\/\/en.wikipedia.org\/wiki\/Radio-frequency_identification\" target=\"_blank\" rel=\"noopener noreferrer\">RFID<\/a>-based cart tracking system, pairing it with Predix capabilities for data ingestion and analytics.<\/p>\n<p>At the beginning, the team identified key locations on the material workflow map and then installed RFID readers in those points. Passive RFID tags were added to more than 400 carts. (The tags have no internal power source, and a reader serves as one.)<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-meetup-detroit.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-meetup-detroit.png\" alt=\"ge-predix-meetup-detroit\" width=\"640\" class=\"aligncenter size-full wp-image-17937\" \/><\/a><\/p>\n<blockquote><p><em>&#8220;Our idea was to basically tag these carts with RFID tags, and in each of these specific locations, we would have an RFID reader that would identify the cart as it comes in. That data is pushed into Predix in real time.&#8221; \u2014Ashok Madhuranath, GE<\/em><\/p><\/blockquote>\n<p>When a cart arrives at one of the scheduled points, the reader identifies it. The <a href=\"https:\/\/www.clearstreamrfid.com\/\" target=\"_blank\" rel=\"noopener noreferrer\">ClearStream RFID<\/a> software running on AWS catches the reads, and the data is then ingested into Predix.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-solution-landscape.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-solution-landscape.png\" alt=\"ge-predix-solution-landscape\" width=\"640\" class=\"aligncenter size-full wp-image-17941\" \/><\/a><\/p>\n<p>The data is pushed to Predix\u2014where the analysis happens\u2014every two minutes. A real-time dashboard shows where each of the carts is, as well as displays information about the parts it is carrying.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-solution-architecture.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/ge-predix-solution-architecture.png\" alt=\"ge-predix-solution-architecture\" width=\"640\" class=\"aligncenter size-full wp-image-17940\" \/><\/a> <\/p>\n<p>The entire tracking system was built using a microservices architecture. On the data ingestion and analytics side, the core toolset includes the Spring framework, Postgres, and Predix UI components, while Microsoft SQL Server and AWS EC2 take their part in capturing initial data. The end-user app has an AngularJS UI; among other technologies incorporated into the system design are Logstash, Kibana, and Postman.<\/p>\n<p>&nbsp;<\/p>\n<h3><span class=\"ez-toc-section\" id=\"Results_and_lessons_learned\"><\/span>Results and lessons learned<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>Since the moment the cart tracking system started to work at Fort Worth, GE has been able to:<\/p>\n<ul>\n<li>Achieve real-time visibility into the facility operations<\/li>\n<li>Change processes by detecting flow issues in the captured data<\/li>\n<li>Optimize resource planning based on cart locations<\/li>\n<li>Replace whiteboards and spreadsheets with a real-time dashboard and tablets<\/li>\n<\/ul>\n<p>Dozens of lost carts were found at the final assembly, including those with materials.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/predix-meetup-project-outcomes-rfid-tagging.png\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/predix-meetup-project-outcomes-rfid-tagging.png\" alt=\"predix-meetup-project-outcomes-rfid-tagging\" width=\"640\" class=\"aligncenter size-full wp-image-17983\" \/><\/a><\/p>\n<p>At the end of his talk, Ashok Madhuranath shared some of the lessons learned:<\/p>\n<ul>\n<li>Stick with architectural simplicity.<\/li>\n<li>Design with RESTful APIs in mind.<\/li>\n<li>Split functionality into microservices.<\/li>\n<li>Go with your language of choice.<\/li>\n<li>Adopt DevOps, continuous integration, and continuous delivery practices.<\/li>\n<li>Be Agile.<\/li>\n<\/ul>\n<p>It was also noted that working with reusable <a href=\"https:\/\/predixdev.github.io\/predix-ui\/\" target=\"_blank\" rel=\"noopener noreferrer\">UI components<\/a> saved the team a lot of development time.<\/p>\n<p>Ashok concluded the presentation with a brief demo of the dashboard.<\/p>\n<p><a href=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/12\/Predix-GE-RFID-cart-tracking-IoT-dashboard-v3.jpg\"><img decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/12\/Predix-GE-RFID-cart-tracking-IoT-dashboard-v3.jpg\" alt=\"Predix-GE-RFID-cart-tracking-IoT-dashboard-v3\" width=\"640\" class=\"aligncenter size-full wp-image-18081\" \/><\/a><\/p>\n<p>&nbsp;<\/p>\n<h3><span class=\"ez-toc-section\" id=\"Want_details_Watch_the_video\"><\/span>Want details? Watch the video!<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<table width=\"100%\">\n<tbody>\n<tr>\n<td class=\"video-details-td\">\n<div style=\"float: right; width: 45%; padding-left: 15px; font-size: 14px;\">\n<p><strong>Table of contents<\/strong><\/p>\n<ol>\n<li style=\"margin-bottom: 4px;\">The concept of a digital thread in supply chain management \/ manufacturing (<a href=\"#wistia_tljnfpsld2?time=90\">1&#8217;30&#8221;<\/a>)<\/li>\n<li style=\"margin-bottom: 4px;\">How does Predix fit into the picture? (<a href=\"#wistia_tljnfpsld2?time=628\">10&#8217;28&#8221;<\/a>)<\/li>\n<li style=\"margin-bottom: 4px;\">Locomotive manufacturing at GE Transportation (<a href=\"#wistia_tljnfpsld2?time=1928\">32&#8217;08&#8221;<\/a>)<\/li>\n<li style=\"margin-bottom: 4px;\">What is the cart&#8217;s role at the Fort Worth plant? (<a href=\"#wistia_tljnfpsld2?time=2176\">36&#8217;16&#8221;<\/a>)<\/li>\n<li style=\"margin-bottom: 4px;\">How were processes organized in the past? (<a href=\"#wistia_tljnfpsld2?time=2276\">37&#8217;56&#8221;<\/a>)<\/li>\n<li style=\"margin-bottom: 4px;\">What does the solution architecture look like? (<a href=\"#wistia_tljnfpsld2?time=2325\">38&#8217;45&#8221;<\/a>)<\/li>\n<li style=\"margin-bottom: 4px;\">What are the project outcomes and lessons learned? (<a href=\"#wistia_tljnfpsld2?time=2869\">47&#8217;49&#8221;<\/a>)<\/li>\n<\/ol>\n<\/div>\n<p><script charset=\"ISO-8859-1\" src=\"\/\/fast.wistia.com\/assets\/external\/E-v1.js\" async><\/script><\/p>\n<div class=\"wistia_embed wistia_async_tljnfpsld2\" style=\"height:320px;width:440px\">&nbsp;<\/div>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<br \/>\n<small>These are the slides presented.<\/small><\/p>\n<p><center><iframe loading=\"lazy\" src=\"https:\/\/www.slideshare.net\/slideshow\/embed_code\/key\/iRNA1xZdmqTwS\" width=\"427\" height=\"356\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\" style=\"border:1px solid #CCC; border-width:1px; margin-bottom:5px; max-width: 100%;\" allowfullscreen><\/iframe><\/center><\/p>\n<p>&nbsp;<br \/>\n<small>This video from GE sheds some light on the company&#8217;s locomotive manufacturing process.<\/small><\/p>\n<p><center><iframe loading=\"lazy\" width=\"560\" height=\"315\" src=\"https:\/\/www.youtube.com\/embed\/SUIYIiZ11Pw\" frameborder=\"0\" allowfullscreen><\/iframe><\/center><\/p>\n<p>&nbsp;<\/p>\n<h3><span class=\"ez-toc-section\" id=\"Related_reading\"><\/span>Related reading<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<ul>\n<li><a href=\"https:\/\/www.altoros.com\/blog\/how-to-create-a-page-layout-and-login-by-using-predix-ui\/\">Predix UI Components: Page Layout and Login<\/a><\/li>\n<li><a href=\"https:\/\/www.altoros.com\/blog\/industrial-internet-is-powering-more-efficient-well-drilling-for-oil-and-gas\/\">Industrial Internet Is Powering More Efficient Well Drilling for Oil and Gas<\/a><\/li>\n<li><a href=\"https:\/\/www.altoros.com\/blog\/the-good-the-bad-and-the-ugly-use-of-iot-who-owns-the-data\/\">The Good, the Bad, and the Ugly Use of IoT: Who Owns the Data?<\/a><\/li>\n<\/ul>\n<p>&nbsp;<\/p>\n<h3><span class=\"ez-toc-section\" id=\"About_the_expert\"><\/span>About the expert<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<div>\n<div style=\"float: right;\"><a href=\"https:\/\/www.linkedin.com\/in\/ashokmadhuranath\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/Ashok-Madhuranath-GE-transportation-bio.png\" alt=\"Ashok Madhuranath, GE transportation bio\" width=\"150\" height=\"150\" class=\"aligncenter size-full wp-image-17954\" \/><\/a><\/div>\n<div style=\"width: 600px;\"><small><a href=\"https:\/\/www.linkedin.com\/in\/ashokmadhuranath\">Ashok Madhuranath<\/a> works as an enterprise architect and senior technologist at GE Transportation. Ashok, who has been coding for 16 years, is now primarily focused on creating industrial solutions. He knows multiple development languages but prefers Java, Node.js, Python, JavaScript, and HTML5. Ashok holds a master\u2019s degree in computer science from the University of Michigan.<\/small><\/div>\n<\/div>\n<p>&nbsp;<\/p>\n<hr\/>\n<p><center><small>The post has been written by <a href=\"https:\/\/www.altoros.com\/blog\/author\/viktoryia-fedzkovich\/\">Victoria Fedzkovich<\/a> and <a href=\"https:\/\/www.altoros.com\/blog\/author\/alex\/\">Alex Khizhniak<\/a> with assistance from <a href=\"https:\/\/www.altoros.com\/blog\/author\/carlo\/\">Carlo Gutierrez<\/a>.<\/small><\/center><\/p>\n","protected":false},"excerpt":{"rendered":"<p>The agenda of a recent Predix meetup in Detroit was focused on IIoT solutions for coordinating supply chains in manufacturing. Ashok Madhuranath, enterprise architect and senior technologist at GE Transportation, spoke about how the Industrial Internet and real-time data can help to identify operational bottlenecks and improve legacy processes within [&#8230;]<\/p>\n","protected":false},"author":24,"featured_media":46849,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"content-type":"","footnotes":"","_links_to":"","_links_to_target":""},"categories":[26],"tags":[873,117,890,647,979],"class_list":["post-17896","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-use-cases","tag-cloud-native","tag-iot","tag-manufacturing","tag-predix","tag-transportation"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Smart Locomotive Manufacturing: Material Tracking with Predix and RFID Tags | Altoros<\/title>\n<meta name=\"description\" content=\"Every day, thousands of locomotive parts are moved from a warehouse to assembly lines at GE\u2019s facility in Fort Worth, TX. 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Ashok Madhuranath, enterprise architect and senior technologist at GE Transportation, spoke about how the Industrial Internet and real-time data can help to identify operational bottlenecks and improve legacy processes within [...]\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.altoros.com\/blog\/smart-locomotive-manufacturing-material-tracking-with-predix-and-rfid-tags\/\" \/>\n<meta property=\"og:site_name\" content=\"Altoros\" \/>\n<meta property=\"article:published_time\" content=\"2016-11-30T15:16:27+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2019-09-23T11:51:18+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.altoros.com\/blog\/wp-content\/uploads\/2016\/11\/Ashok-Madhuranath-GE-Predix-RFID-IoT-featured\u043d\u043e\u0432.gif\" \/>\n\t<meta property=\"og:image:width\" content=\"640\" \/>\n\t<meta property=\"og:image:height\" content=\"360\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/gif\" \/>\n<meta name=\"author\" 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