In production environments, intralogistics often remains a weak point in automation. By using IoT sensors, cloud connectivity, and real-time communication, lean production system specialist ORGATEX closes this gap. The Smart Intralogistics System triggers transport orders and connects intralogistics, production, and IT within an end-to-end information flow.
The challenge: Manual gap in material flow
In intralogistics, there is constant movement: material flows from goods receiving through storage and picking to supply at the production lines. Finished products take the reverse route, moving from the shopfloor to intermediate storage and from there to shipping. While transport routes are increasingly automated, they still depend on manual processes.
Automated Guided Vehicles (AGVs) or driverless transport systems handle material transport, but in many cases the process still has to be initiated manually. This involves the risk of human error, consumes time, and reduces intralogistics efficiency.
Two situations are typical in operations that are not fully automated: either replenishment of raw materials, C-parts, or product components is missing, or fully assembled components and finished products are not collected in time. This creates a gap between technical capabilities and operational reality. Without intelligent sensor technology, real-time communication, and a central platform, the degree of automation remains limited.
The challenges at a glance
- Manual triggering of transport orders
- Missing material replenishment or delayed collection
- Incomplete intralogistics automation
- Time losses due to interrupted information flows
The solution: IoT sensor technology simplifies transport orders
ORGATEX, a company based in Langenfeld (Rhineland) and a specialist in lean production systems, offers a solution for the straightforward handling of transport orders with the OX Location Sensor, the OX Kanban Sensor, and ORGATEX Cloud.
Real-time data for smooth intralogistics operations
ORGATEX’s IoT devices transmit fill levels to the cloud in real time. The system automatically triggers a transport order as soon as a defined threshold is reached—for example, a certain number of bins or a minimum fill level. The AGV system then automatically receives the command to pick up material or deliver replenishment.
- The OX Parking Space Sensor from ORGATEX optically detects the occupancy of storage areas and staging locations in real time. It identifies pallets, containers, or cartons and transmits this information directly to ORGATEX Cloud. Thanks to optical, software-based detection, it can be adapted to individual detection requirements in no time.
- The OX Kanban Sensor from ORGATEX digitizes traditional Kanban racks. Using optical detection, it measures the fill level in each shelf compartment contactlessly and with high precision. This enables automatic monitoring of material inventory and ensures replenishment processes can be triggered in time.
In combination with the OX Label from ORGATEX, an additional layer of automation is created. The digital label displays order information directly on the load carrier and is integrated into the overall system via the cloud. Employees can initiate processes, confirm production orders, or report disruptions—always with up-to-date information.
ORGATEX Cloud acts as the central control hub. Its intuitive user interface allows processes to be configured, alarms to be defined, and visualizations to be created. All data is transmitted in encrypted form and hosted in German data centers in compliance with the GDPR. Communication takes place via the local Thread wireless network or, optionally, via industrial cellular connectivity (NB-IoT/LTE-M).
Stable and secure communication
Thread is a wireless, encrypted mesh networking protocol that is particularly well suited for local communication between small, energy-efficient devices within a building. The devices operate as equal participants and forward information from one to the next, increasing the stability and reliability of the network.
ORGATEX’s Thread-compatible devices can be operated both within a local network and, without any local infrastructure, via cellular connectivity. Installation effort is low, and updates are deployed automatically over the air without IT intervention or production downtime. An included gateway is used to connect to the cloud via cellular communications.
Device management and data analytics in ORGATEX Cloud
ORGATEX Cloud manages all devices, provides interfaces to ERP, MES, and logistics systems, and enables processes to be configured without any programming skills. Users can create their own dashboards, analyse data, and adapt workflows. The cloud is hosted in a GDPR-compliant manner on AWS servers in Frankfurt and ensures encrypted data transmission as well as regular updates.
This shifts control of the solution from IT to the specialist departments. Even smaller companies with limited IT resources can leverage digital intralogistics. Another advantage is the openness of the system. The solution integrates easily into existing infrastructures. Via standardized APIs, data is exchanged bidirectionally with ERP and MES systems.
The result: Practical digitalization for greater efficiency
ORGATEX follows the philosophy of empowering its customers to operate and adapt the systems independently. Changes to processes or workflows can be implemented directly in the cloud without external IT support.
The introduction of the solution includes workshops and training sessions, enabling customers to configure and expand the solution themselves. With its ease of use, open interfaces, and modular architecture, the result is a solution that is ready for immediate deployment.
ORGATEX’s IoT solution stands for practice-oriented digitalization that enables manufacturing companies to automate their intralogistics processes and sustainably strengthen their competitiveness. This allows operations to measurably reduce lead times, avoid downtime, and increase line availability.
Summary of results
- Automatic transport orders via IoT sensors
- End-to-end automation
- Easy integration into existing systems
- Independent adaptation by specialist departments
