R - Retrofit
E - Engineering

• Vision system & automation
• Mechanical optimization
• Digitalization & operator interface

About the project

Toyota Material Handling, a company with an intensive transport system for processing parcels containing spare parts that are sent to their customers, was struggling with frequent barcode reading errors due to incorrect parcel orientation and unfavourable label positioning.

In addition, the existing system offered little flexibility due to the lack of an HMI, which meant that routings could not be adjusted quickly and real-time counter values were not available. Reditech was called in to optimise the hardware, software and mechanical aspects.

Challenge

The existing sorting system faced several bottlenecks:

• Barcodes were not read correctly due to unfavourable placement or twisting during transport.
• Packages rotated during transport, preventing the barcode from remaining in view.
• No HMI interface, so no flexibility.
• No real-time insight into counter data, routing or throughput times.
• An outdated PLC programme that offered limited customisation options.

Our contribution:

Vision system & automation:

• Installation of new Keyence cameras for fast and accurate barcode detection
• Calibration and configuration of vision settings for optimal readability
• Reprogramming of the existing Siemens PLC with a simplified and modular programmer

Mechanical optimisation (in collaboration with Vanas Engineering):

• Mechanical adjustments to the transport system to stabilise parcel orientation
• Expansion of the number of sorting lines and improved throughput logic

Operating interface:

• Installation and configuration of a new HMI
• Real-time remote monitoring of counter data
• Direct adjustment of routings by operators
• User-friendly visualisations tailored to the customer

Results for the customer:

• Significantly fewer barcode scanning errors
• Higher sorting efficiency and reliability
• Flexible routing adjustments in real time
• Complete insight into counters and throughput data
• User-friendly operation thanks to the new HMI
• A more robust and scalable system for future expansions

REDI pillars in this project:

R – Retrofit
Hardware upgrade with new Keyence cameras & optimisations to the transport system
E – Engineering
PLC adjustments, mechanical integration and HMI configuration