Rethinking maintenance: Reduce unplanned downtimes by over 90 percent

Reliable, well-functioning baggage handling systems are crucial for airport operations. Together with belts and individual carrier systems, tilt-tray sorters play a major role in the sorting process. But do you know how many components a tilt-tray sorter can have? Depending on its length, such a versatile sorting system can include up to 300 carriers and several thousand rollers, in addition to other parts. Like all complex technical equipment, sorters demand regular service checks.

Currently, time-based maintenance is the predominant method, involving manual checks to identify damages and evaluate material wear. With this approach, operators replace, for example, all rollers within a set timeframe, regardless of their actual condition. However, to overhaul the entire system, it requires stopping the sorter for several work shifts. This is not only extremely time-consuming and labor-intensive, but also significantly impacts baggage handling processes at airports. Besides, time-based maintenance requires maintaining a large inventory of spare parts on-site. Is there a better alternative to this approach?

Indeed! A far more effective approach is maintenance based on condition monitoring and predictive analytics. With Sorter 360, Siemens Logistics has developed a predictive maintenance solution that captures vibration and distance data from sorters to keep them running efficiently. Powerful analytics software processes the collected data and forecasts the future condition of each carrier and roller, detecting potential failures with up to 100 percent accuracy. With predictive analytics, airports are leveraging the power of digitalization to enhance asset visibility.

Sorter 360 allows service teams to intervene promptly, perform repairs, and replace only defective parts while keeping the sorter system running smoothly. Another important aspect: The solution supports sustainable resource use by scheduling maintenance according to asset condition. This saves material, labor, and cost, and extends component lifespan. By implementing this practice, unnecessary part substitutions can be avoided, resulting in more resource-saving operations. In addition, this approach improves spare parts inventory management and ensures greater efficiency in utilization and optimizes stock levels – in line with the principle of sustainability.

Major hubs, such as in France, India, and the Middle East, have already experienced the benefits of Sorter 360. There, airports could reduce unplanned downtime by over 90 percent, increasing their operational efficiency and ensuring constant and reliable system performance.

Would you like to benefit as well from our predictive maintenance solutions?