Customer success

How BD Rowa reduces the downtimes of order picking systems

Dr. Dorothee Gösswein
Project Manager, BD Rowa

Reliable customer service and continuous improvement are our top priorities. ORAYLIS quickly and efficiently managed to build a digital cloud-based platform providing us with the data from our machines in near real time while ensuring high security standards.

This solution enables our service team to immediately react to technical problems and to proactively prevent malfunctions. It helps us to reduce the downtime of our machines even further, resulting in higher availability our clients can benefit from. We are therefore glad to be able to count on the ORAYLIS team’s support in the future, turning our visions into success.

At a glance

  • Client: BD Rowa Germany GmbH
  • Sector: Industry/order picking systems for pharmaceuticals
  • Project goal: Providing real-time analyses of machine data in applications for service and customers
  • Technologies: Microsoft Azure IoT, Databricks Power BI Embedded

Becton Dickinson Rowa Germany GmbH (BD Rowa) is one of the world’s leading manufacturers of order picking systems for pharmacies, hospitals and pharmaceutical wholesalers. The complex systems of the company based in the small community of Kelberg in Rhineland-Palatinate support healthcare facilities in 53 countries to efficiently store and manage the supply of pharmaceuticals. In this context, smooth service processes are indispensable. Any downtime of the costumer’s systems would lead to bottlenecks in the supply of medicine to patients.

“Since we are a part of the health care system, our work is based on speed, efficiency and safety. This is why offering reliable customer service for our complex systems is of great importance. At the same time, we continuously strive to improve,” Dr Dorothée Gößwein, Project Manager at BD Rowa, says. “Digitalisation and the use of real-time data open up completely new opportunities for us. Just like we wanted to improve our products, we also wanted to be able to have more time for our customers, while technology takes care of the other tasks automatically.”

BD Rowa Automaten - So senkt BD Rowa die Stillstandszeiten von Kommissioniersystemen

Agile methods guarantee reliability

The set goals were clear, but how could the plan be put into practice – especially in terms of technology? As Dr. Dorothée Gößwein explains, “For such a complex project, you need the right partner on your side. The solutions proposed by ORAYLIS immediately convinced us that they would be the best partner for us to implement this project. The team had a clear idea of what our solution should look like. At the same time, the agile working method of our partner always assured us that we were on the right track.”

Data delivered in real-time

ORAYLIS built a state-of-the-art digital platform in the Microsoft Azure Cloud. Previously, machine data was collected on hardware servers in a lengthy process and could only be processed or forwarded at fixed times. The platform now enables a centralised data collection from all customer plants and makes it available in near real time. This applies not only to basic information, error messages or temperature data that the cooling units of the plants continuously send; even extensive videos generated by cameras inside the machines are available immediately. For this purpose, highest security standards in the transfer of data were indispensable.

Avoid malfunctions before they occur

BD Rowa’s support staff can now quickly and efficiently access all of the relevant information via a user-friendly web application. “This enables us to proactively support our customers,” Dr Dorothée Gößwein says enthusiastically. A return channel in the cloud solution even makes it possible to carry out necessary work remotely. Likewise, enquiries to the hotline can be processed with the constantly updated app data without lengthy waiting periods. In addition, the database allows forecast scenarios that can be used to avoid malfunctions in the systems before they occur. “All of these new possibilities help us to further reduce the already low downtimes of our plants, so that our customers can benefit from even higher availability.”

In the future, the cloud approach in Azure will make it possible to flexibly add more and more attractive functions and digital services. For example, BD Rowa’s next step is to use its existing data for an application that allows customers to independently gain valuable insights into the performance of their machines. “Therefore we are very pleased that the ORAYLIS team will continue to support us in our future plans as a guarantee for success ,” concludes Dr Dorothée Gößwein.


turn your data into value.

At a glance

  • Client: BD Rowa Germany GmbH
  • Sector: Industry/order picking systems for pharmaceuticals
  • Project goal: Providing real-time analyses of machine data in applications for service and customers
  • Technologies: Microsoft Azure IoT, Databricks Power BI Embedded
Dirk Ohligschläger
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Customer success

Predictive maintenance: machine builder inspires customers with AI-based forecasts

At a glance

  • Packaging equipment manufacturer enhances its products with data-based services
  • AI-supported forecasts reliably predict machine downtimes and defects
  • Efficiency gains range from warehousing to overall productivity

The business situation of our client

In global competition, efficient production processes are a decisive factor for success. Against this backdrop, digitalisation offers manufacturers of machines and production lines many opportunities to inspire their customers with data-based services from the field of Artificial Intelligence (AI). For example, we implemented prognosis scenarios for predictive maintenance for a globally operating machine manufacturer, which significantly increase the efficiency of the manufactured plants.

The objective of our client was to:

  • Prevent machine downtimes
  • To exclude machine damage
  • Minimise downtimes
  • Identify typical malfunctions
  • Optimise maintenance intervals
  • Improve productivity

The solution for our client

The starting point for our data-based forecasting services is historical as well as current machine data. On this basis, a prognosis model is set up and continuously improved:

  1. We continuously collect the sensor data of the machines
  2. We supplement current measured values with quality-assured master data
  3. We generate diagnostic data on machine problems
  4. We train a machine learning model on the basis of the diagnostic data.
  5. We continuously compare our optimisation algorithms with real-time data.

How data turns into new values

By using our AI-based prognosis model, the machine operators can specifically prevent possible malfunctions and defects. The availability of the machines in operation has improved significantly as a result. But our customer also benefits from the optimisations at its customers: Testing costs and costly recall campaigns are avoided, and warranty costs are significantly reduced. At the same time, customer satisfaction and loyalty have increased.

The improvements for all involved in concrete figures:

  • Machine defects and failures are detected 75% proactively
  • Downtimes have been reduced by 50 to 80%.
  • Maintenance costs have been reduced by 50 to 80%
  • Warranty costs have been reduced by over 50%
  • Inventory costs reduced by 20 to 30%
  • Overtime costs reduced by 20 to 50%.
  • Overall productivity increased by 20 to 30%.


turn your data into value.

At a glance

  • Packaging equipment manufacturer enhances its products with data-based services
  • AI-supported forecasts reliably predict machine downtimes and defects
  • Efficiency gains range from warehousing to overall productivity
Jens Kröhnert
turn your data into value

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Customer success

Digital transformation in heating technology: How to predict malfunctions and reduce consumption costs

At a glance

  • Cloud solution enables continuous monitoring of heating data
  • Forecast scenarios ensure more reliable operation and fewer failures
  • Intelligent heating control reduces costs for the consumer

The business situation of our client

An internationally leading manufacturer of heating systems demonstrates what is possible when data is used consistently. As direct customers of the manufacturer, heating engineers have always been able to act only reactively. System defects could only be detected when they occurred. And the necessary spare parts were usually not readily available, which meant a lot of work for the fitter and cold nights for the heating user.

Together with ORAYLIS, those responsible now wanted to tackle the digital transformation of the company and create new values on different levels through continuous monitoring of the extensive heating data. On the one hand, the objective was to enable the heating engineer to take anticipatory measures and optimise maintenance intervals. On the other hand, it was necessary to improve the settings of the heating system and to reduce consumption costs.

The solution for our client

The core of our solution is a flexibly scalable platform in the Microsoft Azure Cloud. A long-term hardware solution in the company’s own data centre would hardly have been calculable due to the high data volume. On the cloud platform, the continuous stream of operating, configuration and status data of the heating systems is collected and compared with existing system data. The findings are first displayed in a real-time dashboard so that the manufacturer can immediately detect irregularities and proactively intervene. At the same time, typical consumption patterns are identified, such as for the use of hot water or the heating system as such. On this basis, activity and rest phases of the systems can be intelligently controlled. Last but not least, we train forecast models with the current and historical data. These not only make increasingly reliable statements about the expected consumption. Likewise, forecasts on malfunctions and individual wear parts, including recommendations for action, are automatically delivered to the service technician’s mobile phone.

How data turns into value

Everyone involved benefits from the many possibilities opened up by our cloud solution:

Consumers

  • The data-based, automated control of the systems saves up to 20 percent in costs.
  • Continuous monitoring of the heating data ensures reliable system operation

Installer

  • Positioning as a modern service provider that ensures smooth operation
  • Massive savings in time and effort through intelligent supply chains

Manufacturer

  • Positioning as a technological innovation driver and industry pioneer in the heating business
  • Installers and consumers increasingly opt for the manufacturer’s products and remain loyal to them


turn your data into value.

At a glance

  • Cloud solution enables continuous monitoring of heating data
  • Forecast scenarios ensure more reliable operation and fewer failures
  • Intelligent heating control reduces costs for the consumer
Jens Kröhnert
turn your data into value

Let’s get started!

Do you also want to seize the opportunities of digitalisation and stand out from your competitors with data-driven services?

Join #teamoraylispeople

Shape the world
of data with us