Wernsing Feinkost GmbH
Object: Monitoring of production and logistics
Cameras: > 350
Installer: GADCON, Michael Godau
Products: SeeTec Cayuga Infinity + SeeTec BVI Logistic Solution
Whether it be potato products, fruit desserts, salads or soups and stews - the numerous delicatessen products of Wernsing, a food company from Northern Germany are sold through wholesales, numerous food retailers and large discounters in Germany and many other parts of Europe. The family-owned company is committed to sustainability and is constantly expanding both its food product range and the markets and countries that they deliver to.
As a modern, growing family business, Wernsing has already recognized the advantages of a video solution to support its production processes several years ago.
Modern industrial operations need an outer skin monitoring, which reliably protects the production plants and facilities. That also holds true for a food-producing company. But Wernsing quickly understood the additional potential that video technology offers beyond traditional security applications. That’s the reason why they now also use IP cameras for other applications, such as for operational support for their internal process flows.
A production line at a food manufacturer can take up a considerable amount of space: in the production of French fries, for example, it consists of a number of individual installation such as a potato washing station and subsequent sections for peeling, cutting, refining and packaging.
Also, the transport systems between the individual stations sometimes need to overcome rather large distances. Some sections of the production line are difficult to see or reach because of building constraints. In short: An ideal field of application for video technology, because the personnel deployment to monitor such a system completely during operating hours on site would be immense. For this reason, Wernsing decided to install cameras on the production lines and set up de-central, video-based monitoring stations in the production area to monitor the production processes.
The process owner can use the live image on the screen to verify that the system is working properly. The advantage: The responsible employee gets all relevant information in real time, if there are problems within the plant.
In addition to the monitoring stations within the production, the images can of course also be sent and retrieved in a central control room. There, in addition to the live image stream, employees can also search the recorded video material for unwanted events or malfunctions. Today, up to 45 users simultaneously access the image data of the over 350 cameras installed.
The planning and installation of a video system of this size, which is also used for production monitoring, requires the support of competent partners. In this case, Wernsing relied on the professional help of GADCON.
Right from the start, Wernsing was aiming for a complete security solution that includes not only the video system but also the building management system (advancis Winguard) and access control, thus offering them additional added value for their infrastructure investments. As a certified SeeTec partner, GADCON was also able to present yet another solution package to add, that was aroused interest at Wernsing: the linking of camera images with process data, which are incurred for example in order processing and shipping.
This approach, which is becoming increasingly popular especially for applications in logistics, also convinced the decision-makers at Wernsing. That's why for shipping, the food company now utilizes SeeTec BVI, an intelligent software platform that links video data with other relevant production data. In the case of Wernsing, this happens as follows: For the order processing, dispatch and loading several scan spaces are distributed on the factory premises. The outgoing goods are scanned several times during the shipping and loading process and compared with the order data stored in the enterprise resource planning system. Each scan gets "married" to the video captured at the time of the scan. In the event of damage, it is thus possible to analyze where it has occurred in the automated logistics process. In addition, the video images can also be used in cases of customer complaints in order to prove that the goods were undamaged as of loading and had arrived at the correct loading bay.
The system has already proven itself within a very short time. Any shortages within the logistics process can be detected very easily and immediate action can be taken to improve the process. For Wernsing, optimizing their procedures with video images directly increase customer satisfaction sustainably. And thus the delicatessen producer can fulfill its quality promise – which extends far beyond the quality of its product only – almost “in passing”.
The project at Wernsing grew quite extensively already during the planning phase. Initially the plan called for roughly 110 cameras to be installed. However, it soon became clear that this number would not be sufficient due to the optimization potential and the new use cases for video images that had been presented to the customer in the jointly conducted project planning.
That's why more than 350 cameras are in use today, and Wernsing is counting on SeeTec also for future expansion in production. Mr. Seckin Bayindir, project manager at Wernsing, explains: "The system has been very well received by the production staff, as the decentralized monitoring of the production facilities reduces their work load and adds convenience. They like the new system, because they were involved in the planning right from the beginning. It was a win-win situation because it is the staff that works on a production line on a daily basis that knows best where the critical areas are and where problems can occur." But Mr. Bayindir also has words of praise for the project partners Gadcon and SeeTec: "The experience and expertise that both companies brought to us enabled us to bring the project to a successful conclusion. And the cooperation with SeeTec and GADCON was always at eye level, even when it came to developing special solutions."
“Through extensive use of the system, we always have new ideas for new functionalities that we like to see implemented and that we report back to SeeTec. I am very confident that our feedback will also help other customers benefit from new functions in the future.”
“It is always a challenge to plan a project like the one we realized here. But in the case of Wernsing it was an exciting challenge that profited from the right technology being available and decision makers who had a clear vision of what they wanted the technology to accomplish for them.”
“It was really exciting to see this project grow. And change - for the better! I am proud that we have partners like Gadcon that challenge us, that make us think and create. Because only in a close cooperation we can excel together, for the benefit of our end-customer.”