Unmanned Weighbridge

1
Weighbridge Automation Blueprint
Imagic Solution

• Unmanned Weighbridge System

2
Project definition-1

• The UMS RFID Solutions is intended to implement
  In-plant Automation. following modules to be
  implemented based System
• Installation and Configuration of Requested
  Modules
• Gate In / Card Issue
• Weigh In first Weight
• Loading / Unloading
• Weigh Out Second Weight
• Gate Out / Card Submit
• Unmanned Weighbridge Solutions Aimed at speeding
  up throughput of vehiclesTrucks, improving
  security and extending weighbridge operational
  periods, together with improving and simplifying
  data collection and distribution. Our
  Technologies employed include Ethernet
  communication for remote access, LAN, automatic
  vehicle recognition systems, smart card or key
  readers, wireless interfacing
• Unmanned Weighbridge Process Systematically

RFID
3
Project definition-2

• Gate In
• Gate Pass Generation (RFID Card issuing)
• Generate Gate Pass Process Driver need to
  register his vehicle at gate in and this
  registration will take care of all needed details
  e.g. driver name, vehicle Truckno., supplier
  name, customer name, etc.
• Generate Gate Pass for this VehicleTruck and
  Register/Capture its Reporting Time. After
  registration process, gate operator will issue
  RFID Card to the truck driver. Driver will
  receive the RFID Card and proceed to check in
  office. IP Camera captures truck license plate
  number.
• Weighbridge In/out
• First Weighment Driver will drive truck onto
  the weighbridge. Driver start weighment process,
  Driver taps RFID card on RFID Reader, if card is
  valid/Authenticated then Barrier Gate will open
  otherwise it will not open.
• If the truck not in proper place system will
  announce and instruct him and Barrier Gate will
  not open. Staff from control room will advise
  driver and trouble shoot.

4
Project definition-3

• Loading / Unloading
• Dispatch Officer verify the product details like
  quantity, type and other parameters for
  loading/unloading.
• Gate Out
• RFID Card Submission Process. After finishing all
  the Weighment process, driver will submit RFID
  Card to the Gate Operator and issue delivery
  order document for outbound and issue weight
  ticket for inbound material and stamp truck
  leaving time from the plant and system will also
  register the time out. After submit RFID Card its
  free for another Vehicle process.
• Reports

• Dashboard Reports optional
• Master Reports
• Date Time Reports
• Product Reports
• Vehicle Reports

• Ticket No Reports
• Product Summary Reports
• Customer Summary Reports
• Shift Reports

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Flow Process
QC Check For Confirm Load Unload
Weight Out Raw Material
Weight In Raw Material
Unload / Load Raw material
Gate Out
Gate In

• register truck
• generate RFID
• snap truck ID

• tab RFID at RFID reader at dispatcher counter
• Information of order show to dispatcher
• Record dispatching quantity each channel

• tab RFID at RFID reader at dispatcher counter
• Information of order show to dispatcher
• Barcode reader read barcode on seal then record
  to system

• tab RFID at RFID reader housing case
• the weight system perform weight out

• driver return RFID to staff
• tab RFID at RFID reader to get information
• printout document for driver

• tab RFID at RFID reader housing case
• the weight system perform weight in

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Data Backend
ERP Backend
Interface
Load Material
Solution
Gate In
Weight In
Seal(bulk only)
Weight Out
Gate Out
Unload Raw material

• Stand alone system off line from ERP
• Upload batch data from Backup system to ERP

BCP
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RFID Reader Boom Barrier LED Display Traffic light Sound System IP Camera Position Sensor Barcode Reader
1 0 0  0  0 0 0 0 
Gate In

• Gate IN Process -
• Vehicle Truck reach on Gate for Loading /
  Unloading
• Driver provide require document to Gate IN Staff
• Gate in staff select vehicle type and enter ERP
  Number on Gate Screen and fetch require data from
  ERP
• RFID System ERP number link with RFID card and
  save data
• On saving time RFID System
•  
• Note-
• We have three Type of Process (FG - Finish
  Goods-SP), (RW- PO-Purchase Order), (Other
  Goods)
• We use two type of loading Vehicle Truck, Bulk,
  Flatbed Truck
• Driver come without shipment number, sales order,
  PO not allow enter to Check in office,

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RFID Reader Boom Barrier LED Display Traffic light Sound System IP Camera Position Sensor Barcode Reader
1 2 1  6 1 2 3 0 
Weight In

• Weighment Process -
• Vehicle reach on weighbridge for weight in
• Driver tab RFID card on reader, the system
  display details of vehicle number ERP number
  will be fetched from database, weight pick from
  weighbridge and display.
• On LED display vehicle number and live weight
• Sound system announce vehicle number after tab
  RFID card on reader
• Camera capture stable image automatically on
  Weighment saving timestamp
• Boom barrier open after data save successful
• On green light indicate weighment process
  completed
• Driver move to loading / Unload Process
• Capture Drive image when Press Button and Confirm
  Weight Optional
• Note-
• Tolerance As per company Policy

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RFID Reader Boom Barrier LED Display Traffic light Sound System IP Camera Position Sensor Barcode Reader
1 0 0 0 0 0 0 0 
Load / Unloading

• Loading / Unloading Process -
• Loading point have 1 working station
• RFID reader Connected to PC,
• Based in queue driver reach at loading bay and go
  to hand in RFID with loading document to packing
  staff at working station.
• Staff tab RFID card on reader the system will
  display require detail on screen(customer name,
  ERP number, material name, material code,
  quantity then staff confirm loading, system
  capture start loading timestamp
• Staff hold RFID card and loading document till
  loading complete
• Once loading completed then driver go to working
  station to get RFID card and loading document
  back, loading staff tab RFID card on RFID reader
  and completed loading of vehicle and return RFID
  card and loading document to driver, then driver
  can move to next station
• Note-
• Function cancel load is required
• Interface With Flow Miter and Control loading
  unloading as per DO Qty Optional

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RFID Reader Boom Barrier LED Display Traffic light Sound System IP Camera Position Sensor Barcode Reader
1 2 1  6 1 2 3 0 
Weight Out

• Weighment Process -
• Follow same as the process weight in
•  Note-
• Check Gross tolerance of As per Product type
  Based and Company Policy
• If vehicle not under tolerance then they ask to
  weighbridge command center officer to advise
• Inbound raw material not allow to cancel weight
  out
• Capture Drive image when Press Button and Confirm
  Weight Optional

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RFID Reader Boom Barrier LED Display Traffic light Sound System IP Camera Position Sensor Barcode Reader
1 0 0  0  0 0 0 0 
Gate Out

• Gate Out Process -
• After complete weight out driver move to gate out
• Driver return RFID card to gate officer
• Officer tab RFID issue gate out and print out
  document
• Driver sign off document
• RFID card Free For New Vehicle

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Flow Chart of Unman Weighbridge
.
Barrier Gate
Truck
RFID Reader
Photo Sensor
Unmanned Indicator
Junction Box
Database
CCTV Camera
Weight Display
Sound Secker
RFID Reader
PC
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Project Deliverable

• User Acceptance Test Case
• Software data reconcile with ERP accuracy 100
  (optional)
• Software user interface follow requirement
• Crystal report
• Hardware accuracy 100
• Training material
• Trouble shooting material
• Software handbook

14
System Benefits

• No need to operator, to operate weighbridge
• If truck is not in proper place weighment is not
  further proceed.
• No need to supervise truck position in proper
  place or not.
• Truck weighment is securely weighment proper
  weight.
• Supervisor get report for audit trail data, if
  any one modify weighment data.
• CCTV photo capture facility capture truck real
  time photo for security purpose.
• Denied manual entry mistake by operator.
• Set Auto check Point for DO/PO Weight and allow
  that pre-defined Qty weight only.
• Pre-set weighbridge for truck weighment
• Pre-set weight variance for check point in
  truck out time
• Operating Cost Saving,

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Video Link
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