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A. Kempf: Doubling
throughput and capacity
Bosch Rexroth: Greater
productivity in assembly line supply
Cover story retail Manufacturing Pulp & paper
4 10 14
Issue 1/2014
Company magazine
ICT: Speedy solutions
for paper towels
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Franz Bauer-KieslingerManaging Director, Salomon Automation, Friesach/Graz
Dear readers,
It was with great interest that we read a recent study onleading providers of logistics software, focusing on cus-tomer satisfaction, brand image and recognition. Andwe were particularly pleased with the results.
Of course, we were not surprised to see that criteriasuch as simple implementation, special-purposefunctions and customer-specific solutions play animportant role when choosing logistics software. Butwe were pleasantly surprised to find out just how highly
we scored on precisely these points.
There is nothing worse than working with outdated pro-cesses, not being state-of-the-art or simply failing toevolve. We have made it our goal to meet our custom-ers requirements to the letter, aided by our innovativeWAMAS logistics software and our status as a certifiedSAP Service Partner. Our WAMAS and SAP EWM solu-tions are successfully deployed in scenarios around the
world whether in manual warehouses, pallet or smallparts storage systems, or highly complex automatedand dynamic distribution systems. We are committed tofinding effective answers to customer challenges andchanging market environments; to setting new trendsand always staying at the leading edge.
We have pooled our IT expertise to create a central soft-ware headquarters for the entire SSI Schaefer Groupin Friesach, near the Austrian city of Graz. In future, it
will be supported by SSI Schaefer sites in Timioara(Romania), Dortmund (Germany) and Giebelstadt(Germany). Moreover, we will continue to expand anddevelop our existing high-level IT expertise in Charlotte(USA) and So Paulo (Brazil).
Our goal is to deliver the best possible solutions forour customers.
Editorial
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4
Contents
Cerebos/Diplom-Is/PT. Sinar Sosro
Project
12 Food industry
ICTProject
14 Pulp & paper
PACCAR Parts Europe/Autoparts De Jonghe/
atzert:weber/VW China
Project
16 Automotive
BLG Handelslogistik/INL Dubai/Khne + Nagel
Project
18 Logistics service providers
Showrooms in Asia/Software headquarters Salomon Automation
Research and testing facility
3D-MATRIX Solution
Containers in the spotlight
Expertise
News
Solution
Interview
20 Inside SSI Schaefer
4 RetailA. Kempf: Two-phase shippingautomation doubles throughputand capacity
SCP automatic picking solution
Blecha/Brammer
Cover story
Solution
Project
Leonhard Heyden/Bosch Rexroth/Brady Corporation
9 ManufacturingProject
14
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Two energy-efficient storage andretrieval devices work in the aislebetween the order and tour buffers.
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Balingen, Germany.Since 2002, beverage whole-saler A. Kempf has been a fully owned subsid-iary of supermarket operator Edeka Handels-gesellschaft Sdwest, providing logistics servicesto Edeka stores in southwest Germany.
The company operates two warehouses, one of
which is located in the German town of Balingen.At peak times, 124,000 beverage crates, boxesand packages and as many as 160,000 on par-ticularly busy days are shipped from the distribu-tion centre every 24 hours. To keep pace with thislevel of turnover, A. Kempf needed to automate itsprocesses without disrupting ongoing operations so they turned to SSI Schaefer in Giebelstadt.
By automating processes and installing a two-phase shipping concept, we were able to boostefficiency and ensure our deliveries are alwaysready on time. Plus, by creating automated orderand tour buffer storage areas, we can now pre-
cisely time the provision of goods for shipment minimising standby time for trucks. In fact, turn-around has fallen from up to four hours to lessthan one hour on busy days, explains ChristianMelchior, business unit head at A. Kempf, basedin Offenburg.
The solution comprises two storage areas andtwo powerful, energy-efficient storage and re-trieval systems working together in one aisle.SSI Schaefer implemented a fully automated pal-let transfer system that enables pallet sequencingin line with truck routes significantly enhancingefficiency. This meant dividing the outgoing goodsstorage area in two: pallets are first brought toan order buffer, and are then transferred to atour buffer before collection. The order buffer ismade up of a flow rack system divided into foursections, each with eight channels. After picking,the pallets are transported to one of the systems1,152 positions, spread over three levels. Thetour buffer offers a further 720 positions, equiva-lent to the capacity of 16 trucks.
The picked pallets enter the conveyor systemvia two feed stations at floor level, before beingtransferred to the automated two-phase process
in the interim storage area. After the pallets havepassed through a wrapper, an applicator labelsthem with EAN barcodes and a list of contents.A vertical conveyor then transports the goods tothe right storage level in the order buffer.
The pallets are moved from the order buffer tothe tour buffer in preparation for shipment.SSI Schaefer paid careful attention to the designof the load handling devices used in the storageand retrieval systems, in order to ensure seam-less transfer and reliable transport of the bever-age pallets in the aisle between the two buffers.
Two motorised roller tracks are equipped withan electric pneumatic system that separatesthe pallets from each other, so that each palletcan be handled individually. Both storage and re-trieval devices can move up to two pallets at atime. Based on this innovative system, orders canbe sequenced in line with truck delivery routesand are rapidly transferred to the goods shippingarea as needed. On the basis of pre-defined re-quirements, WAMAS logistics software generatesthe ideal sequence for placing pallets in the tourbuffer so goods are in the right order whenunloading the trucks at each store.
By reducing setup times, automating labellingand pallet transfer and enabling automatic trig-gering of processes in the order and tour buffers,A. Kempf has increased throughput from 90 to240 pallets per hour, and has almost doubled cap-acity in the interim storage area. And thanks tothe increased capacity offered in the new facility,the company has plenty of room to grow.
Two-phase shipping automation doubles
throughput and capacity
SSI Schaefer has created an innovative two-phase automated shipping buffer systemfor products waiting to be shipped at beverage wholesaler A. Kempf doubling through-put and capacity, and making it possible to load goods in line with store layout.
Cover story retail
At two floor-level double-pallet feed-in stations,the picked pallets are transferred to the con-veyor system where the automated two-phaseprocess begins.
A transfer carriage moves thepallets from the vertical con-veyor to the order buffer.
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Retail
The retail sector faces a number of challenges, such as anever-larger variety of products and ever-smaller batch sizes.But by choosing the right internal logistics processes andtechnologies, companies can gain a competitive advantage.Efficient processes and systems make all the difference.The Schaefer Case Picking System (SCP) is a unique, award-winning solution that compiles deliveries completely automat-ically. This end-to-end, modular system is designed to meet theneeds of the retail sector, and can be extended as required.
The technology behind the scalable SCP is a compact, highlydynamic buffer system for throughput of 30,000 to more than
500,000 packages per day. Here, items from the storage palletare automatically separated out, and placed on trays in layers tobe stored with all movements designed to protect the goods fromdamage. The fully automated system can pick individual items fromthe tray if required, and can retrieve stock from more than one tray
USA. Around 20,000 items, including food and household goods, arestored in the distribution centre of warehousing, picking and transpor-tation specialists ES3 in York, Pennsylvania. Up to 1,300 pallets aredelivered to the site daily, with throughput totalling over 100,000 boxesevery 24 hours. SSI Schaefer was tasked with designing an intelligentend-to-end system for fully automated food industry processes for ES3 from goods receipt through to storage and space-efficient pallet as-sembly. Now, ES3 enjoys efficiency on a whole new level, thanks to theSCP concept. SSI Schaefer designed a made-to-measure solution thatmeets customer-specific requirements including a pallet packing heightof up to 2.4 metres.
Germany.When discount supermarket giant Lidl decided to extend its logistics cen-tre in the German town of Kirchheim/Teck, the SCP system was the obvious choice.Not only does SCP boost efficiency, it optimises use of storage space and trans-portation resources, and makes life easier for supermarket staff when stocking theshelves. In addition to the SCP system itself, Schaefer also supplied Lidl with afive-aisle high-bay warehouse complete with around 15,000 pallet positions, and aSchaefer Tray System (STS) with 16,000 positions over five levels. Lidl is the firstreference customer for SCP in Europe. For this project, SSI Schaefer fulfilled specialrequirements for the customer in terms of family grouping and sequencing in linewith store layout areas where other logistics specialists were not able to deliver.
Unlocking greater efficiency for
retail and food industry logistics
By positioning multiple STS vehiclesover one another in the Lidl ware-
house, efficiency is enhanced and theavailable space is maximised.
The nine robotic palletisers in ES3s SCP facility
arrange boxes in line with orders.
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Retail
at a time. And at the buffer system stage, it is possible tosequence goods in multiple levels, so that orders are readyto go and are packaged based on store layout.
In addition to the SCP racking system and conveyors,Schaefer also offers a host of tried-and-trusted solutionssuch as the Schaefer Tray System (STS) and machine vi-sion technology. De-palletising, palletising and wrappingsystems round out the offering. And the integrated SchaeferPack Pattern Generator (SPPG) software ensures optimalpallet composition.
The versatile SCP system meets the diverse requirements of a
range of customers as demonstrated in a number of success-ful international reference projects.
USA. In early 2012, a US supplier of foodsector services installed an SCP system inits logistics centre. The facility now benefitsfrom highly dynamic processing of small or-der volumes (picking of individual items andcases). Around 12,000 items are storedin the logistics centre for delivery to retail-ers, with around 4,000 boxes and contain-ers passing through 24 Schaefer CarouselSystems (SCS) every hour. The two SCPmodules significantly boost efficiency. Thecustomer was impressed with the results;
so much so that they have recently taskedSchaefer with a follow-up project.
Switzerland. Migros-Verteilbetrieb Neuendorf AG (MVN AG) is the centrallogistics partner of Migros, the largest retailer in Switzerland. The frozengoods department specialises in logistics for the food industry. Withthe SCP system created by SSI Schaefer in the refrigerated warehouse(-28 Celsius), it is not necessary to label goods with barcodes or RFIDtags. From start to finish, all processes run on the basis of machinevision technology. Once goods come into the warehouse, data is cap-tured on the number of packages, best-before dates and delivery dates,for example, and compared with the master data in the IT system. Atteach-in stations, employees record the weight, volume and dimen-
sions of the current delivery, updating item information if necessary. Themaster data for each item is used to automatically set the parametersof the mechanical system components in the process chain. Moreover,machine vision technology performs all detection and monitoring tasksduring warehousing and picking, such as recording volumes, positioningthe items or automatic itemcounting for manual picking.
When goods are received, they undergoa teach-in process to update master
data in the IT system.
Robots ready and waiting for deployment ina major new international SCP project.
Fully automatic, store-friendly palletising: the system combineshigh picking capacity with processes that protect the integrity
of the products.
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Retail
Neunkirchen, Austria. Founded in 1986, inter-national company Ingrid L. Blecha specialises inaluminium pipes and pipe fittings, fence systemsand profiles. The company serves customers inaround 60 countries in a host of sectors fromthe aluminium, metal and CNC industries, toautomotive suppliers and fence systems manu-facturers.
At Ingrid L. Blechas site in Neunkirchen, Austria,the aluminium products are developed, stored,picked and dispatched. Faced with a lack ofspace and in need of additional capacity to meet
future demand, the company decided in 2012to build a central spare parts store and extendits newest warehouse. They hoped to improvethe maintenance infrastructure in the process.SSI Schaefer was tasked with the project, install-ing a 14-metre-high storage lift that meets all thecompanys requirements. With the new LogiMatlift, Ingrid L. Blecha is fit for the future. Not onlydoes it require very little space, it also features asmart, high-quality and cost-efficient design thatensures reliable processes. Plus, there is room inthe new lift for all maintenance components andspare parts.
The project stood out for another reason, too:due to the site layout, SSI Schaefer did not in-stall the LogiMat inside the building but on theouter faade of the warehouse, fitting fire protec-tion cladding around the steel frame. The unique
design kept costs for the warehouse extensionto a minimum. Moreover, the LogiMat integratesseamlessly into the existing infrastructure and fireprotection programme it is lined with protectivepanels and features an integrated smoke ventila-tor and automatic fire door.
But thats not all. Supported by the dedicatedLogiMat Logisoft software, the system can pre-
cisely pinpoint each items position and auto-matically take inventory of the small parts. Thegoods-to-picker strategy makes picking itemsmore efficient and precise. And the new systemenhances safety in the warehouse to boot.
Haarlem, Netherlands.Brammer Nederland BV, a leading distributor of mechanical components forindustry, has just moved into its new, central distribution centre in the Dutch city of Haarlem. To ensureseamless internal and external transportation of parts, the company opted for storage and transportcontainers from SSI Schaefer.
1,000 of these containers now support Brammer in storing and picking goods, andtransporting them between its new distribution centre and the 17 service centresdotted across the Netherlands. 200 containers pre-fitted with eight dividers holdexpensive, fragile items, ensuring goods are protected as they safely and noise-lessly make their way along the conveyor belts.
Even the standard version with a reinforced, ribbed base can support a weight ofup to 50 kilos. It is ideal for heavy components. Thanks to the flexible, ergonomic
handles, the containers are very easy to work with, and they are designed to fit thesize of a euro pallet. And with the Brammer logo emblazoned on the side, they area great calling card for our company, explains Eric Dijkstra, Director of Operationsat Brammer.
Intelligent design
Keeping goods safe while on the move
Unique LogiMatstorage lift design enhancessmall parts picking processes.
This design meant that the storage lift couldbe higher than the building.
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Manufacturing
Hachenburg, Germany. Successful internationalbriefcase and handbag manufacturer LeonhardHeyden operates ten stores across Europe andsells its products through countless retailersworldwide. The mid-sized player releases four col-lections on the market every year. All items mustbe ready for delivery at short notice, in line withorders from outlets and customers labelled,modified as required, and packaged. Seasonalpeaks in demand and rapid changeover from onecollection to the next are the norm.
When Leonhard Heyden decided to consoli-date three existing sites at a single, central3,000-square-metre warehouse in the Germantown of Hachenburg, they had a number of goalsin mind. They needed to ensure they had suffi-cient products on hand to meet demand, while en-hancing routes, minimising incorrect orders andensuring seamless processes and traceability.Moreover, they wanted the possibility to accessthe warehouse systems from company head-quarters, in order to remotely monitor and con-trol processes. To meet these complex require-ments, Leonhard Heyden decided to implement
SSI Schaefers WAMAS GO! warehouse manage-ment system.
The system is based entirely on the success-ful WAMAS logistics software. WAMAS managescomplex processes in all manner of warehouses,from manual to fully automated, and WAMAS GO!is tailored specifically to the needs of mid-sizedcompanies. This made it ideal for LeonhardHeyden, which has a mid-range turnover and man-ual warehouse system. The new software manages,
plans and monitors all flows of goods, informationand resources and supports all logistics pro-cesses from goods receipt and picking through topackaging, shipment and tracking.
The IT system is combined with a manual storagefacility from SSI Schaefer, tailored precisely toLeonhard Heydens requirements. A modularshelving solution with around 1,800 positionsholds all fast-moving items, packaged individuallyand grouped by product range. End-of-line itemsare stored in the rear of the warehouse using thechaotic storage principle. In the outgoing goodsarea, SSI Schaefer installed eight height-adjust-able, ergonomic packing stations. Two are re-served for packing products for shipping to stores,two are used for returns management, and at theremaining four, employees modify the high-endleather bags before they are dispatched.
When new supplies arrive, they are stored in box-es on pallets in two halls. In one hall they arestored several rows deep, organised by productline (slow-moving items); in the other, they arekept on mixed pallets for direct access (fast-mov-
ing and regular items). WAMAS GO! supports end-to-end management of all products, directly onthe pallets.
Now that all processes are managed byWAMAS GO!, we have achieved time savingsof around 30 per cent. In addition, the systemensures full visibility into inventory and end-to-end traceability. Plus, we have seen a significantreduction in the error rate, reports ChristianUsinger, head of logistics at Leonhard Heyden.
Enhancing transparency with WAMAS GO!
At bag manufacturer Leonhard Heyden, the WAMAS GO! warehouse managementsystem, together with a made-to-measure storage facility, ensures transparentprocesses and end-to-end monitoring across the entire supply chain.
All fast-moving items are stored on shelves in around 1,800positions, individually packaged and grouped by product line.
Items are prepared for dispatch at the packing stations.Around 150 - 400 orders are processed each day.
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Boosting productivity in assembly line supply
Hassfurt/Augsfeld, Germany. With over 37,500employees around the globe, Bosch Rexroth isone of the worlds leading suppliers of electricdrive and control technology. In Germany, thecompany operates 17 production facilities, fourregional sales centres and eight service centres.The complex in Hassfurt/Augsfeld, founded in1961, includes a manufacturing and logisticssite, and part of the Mobile Applications businessunit. It was here where Bosch Rexroth decided toinstall a new interim storage area for the produc-tion of mobile control units.
The two-aisle automated small parts store pro-vides interim storage for the production facility,and is used to hold items such as brakes, sta-bilisation modules, hydraulic components andvalves. Capacity totals 10,488 positions, com-
prising standard containers in a range of sizes.The new automatic small parts store replaces anold facility where goods were stored on euro-pal-let-sized trays. The company was looking for a newsolution that would significantly reduce handlingtime and effort, and markedly boost flexibility.In SSI Schaefer, we found a partner that offeredus the perfect solution, delivering all the improve-ments we were looking for and meeting ourrequirements in terms of picking, explains DrLars Biester, head of logistics at Bosch RexrothsHassfurt/Augsfeld plant.
While work was underway on the automated smallparts store, SSI Schaefer also integrated thewarehouse management system into the centralSAP-based ERP environment. Now that the projecthas been successfully completed, it is possible to
Since December 2012, Bosch Rexroth has been operating a new interim storage areafor its mobile control units production facility in the German town of Augsfeld. Themanufacturer required greater performance and flexibility and SSI Schaefer was ableto deliver, with a concept based on new containers that are significantly easier to use.
After successful implementationof the new system, it is now
possible to perform around 600incoming goods processes and
2,500 outgoing goods processesevery day, with operations split
into three shifts.
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Manufacturing
A first-class relocation
Greystanes, Australia.Founded in 1914, the Brady Corporation is theglobal leader in labels and signs that identify premises, products and
people. Its portfolio includes labels, software, printing and data cap-ture systems for the manufacturing, electronics and telecommunica-tions industries. One of the companys international sites is located inthe town of Greystanes near Sydney.
Now, Brady Corporations Greystanes facility boasts a new central dis-tribution centre covering around 10,000 square metres. The new centre consolidates two existing sites that were beingphased out. Brady Corporation turned to SSI Schaefer for support: they were looking for a flexible partner who would coord-inate the entire move and the consolidation of the two warehouses all while working in close contact with all stakeholders.
Experts from SSI Schaefer implemented the ideal solution. They needed to take into account the fact that BradyCorporation requires storage for a wide variety of different items. The new system ticked all the boxes, particularly interms of flexibility. An R 3000 modular shelving system featuring around 4,000 positions and fitted with a state-of-the-artsprinkler system is now available for the storage of items in the distribution centre. The pallet racking units offer a further
5,000 positions.
The new facility has significantly increased picking speed, so every order can be shipped on time. This means customersare happier, too. The entire project was completed on time, and provides Brady Corporation with plenty of scope for futuregrowth.
execute around 600 incoming goods processesand 2,500 outgoing goods processes each day,with operations split into three shifts. A pickingstep takes a maximum of one minute. Plus, hand-ling each individual container is now far easierand more ergonomic.
Equipped with telescopic load handling devices,the storage and retrieval units are designed towork with double-deep storage and can supporta weight of 100 kilos. The parameters of the loadhandling devices can be flexibly configured, andthey can safely move containers and trays ofup to 50 kilos. There are practically no limits tothe shape or the surface material of the articlesto be stored. On average, each storage and re-trieval device transports around 320 containersevery hour.
Once the requested small container has arrivedat one of the four picking stations, the employ-ee removes whatever he or she requires andplaces it in the order container. The containeris then returned to the small parts store and thewarehouse management system records that itis available once again. Parts are subsequentlydelivered to the assembly lines as required, onthe basis of the milk run principle.
The two-aisle automatic small parts store ser ves as an interim storage area upstreamof the production lines for items such as brakes, stabilisation modules, hydrauliccomponents and valves.
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Food industry
Laem Chabang, Thailand. Founded in the UK inthe 19th century, the Cerebos Group produces andmarkets food items such as salt, instant products,coffee, and several major beverage brands in Asia.
Around 35 years ago, Cerebos began producingBRANDs Essence of Chicken in Thailand. Cerebosbusiness in this country primarily consists ofsupplying nutritional supplements to customersin some 18 countries. This means there are largequantities to be stored before shipping.
One of the organisations first sites in Thailand, lo-cated in the Nonthaburi province, is now the lead-ing manufacturing facility for BRANDs Essence ofChicken. Recently, Cerebos decided to increase itsproduction capacity, opting to extend its existing fa-cility at the Laem Chabang Industrial Estate in theChonburi province. The company chose this plantbecause of its excellent logistics infrastructure.
SSI Schaefer was tasked with providing systemsfor the new warehouse. To find the ideal solution
for Cerebos, experts from the intralogistics playermeticulously studied existing inventory processes,including shipping data for each and every product.
Since the BRAND products are picked in batchesand there are only a small number of stock-keepingunits, SSI Schaefer recommended a combinationof the Schaefer Orbiter System (SOS) and a palletracking solution. The system has a pallet depthof 28 and a pallet height of five. Furthermore, theracks are designed to accommodate an additionalfive pallets on each level, taking the total number
of positions to around 5,500.
After careful analysis, decision makers at Cereboschose to implement the SSI Schaefer warehousesolution. In addition to significant capacity gains,the high-performance system reduces operatingand maintenance costs. Whats more, profession-als from the SSI Schaefer customer service teamare on hand to ensure everything runs smoothly with zero errors.
Schaefer Orbiter System accelerates inbound
and outbound items in the food industry
Schaefer OrbiterSystem with a palletdepth of 28.
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Food industry
Gjellersen, Norway.Diplom-Is is the largest manu-facturer of ice cream in Norway. In order to im-prove flexibility, efficiency and cost-effectiveness,the company decided to restructure its logisticsprocesses. In the past, pallets of finished goodswere strategically distributed to a number of ware-houses on the west coast of the country beforethe items were sold. Over time, however, this ap-proach proved to be both time- and effort-inten-sive. Flexibility is of the essence in this industrybecause ice-cream sales depend heavily on theweather and the time of year.
For this reason, Diplom-Is wanted to consolidateits depots at one central distribution centre inGjellersen. From here, frozen and non-frozengoods can be shipped significantly faster and
more cost-effectively to customers. This is downto a semi-automated picking and packing systemfrom SSI Schaefer. This smart combination of con-veying and pick-by-voice technologies not only upspicking speed, it also reduces error rates.
A major highlight of the project was that it wascarried out during regular operations at tempera-tures as low as -28 Celsius. Leveraging state-of-the-art conveying technology, items are now fedthrough the sorting process on multiple levelsand transported to the right dispatch tracks.Goods are then manually picked from the palletsto the boxes using voice commands. The result:even in high season, Diplom-Is can fulfil all orderscost-effectively and on time, with no need to hireadditional staff.
Greater efficiency through consolidation
New shuttle system
for tea productsCakung, Indonesia.Using the Schaefer Orbiter System (SOS), foodmanufacturer PT. Sinar Sosro has maximised its warehouse capacityat its Cakung site on the Indonesian island of Java. The companyuses this facility to distribute its ready-to -drink tea products acrossthe country and beyond.
To increase warehouse capacity at this space-limited site, PT. SinarSosro has introduced a shuttle system with 32 channels, 16-deepand three-high storage enabling an overall capacity of around 1,500pallet positions. Three Orbiter units move the items around the ware-house, ensuring greater efficiency, reliability and increased safety.
Diplom-Is increasespicking speed andreduces error rateswith a new conveyorsolution.
A new semi-automated warehouse solution streamlines processes for ice-creammanufacturer Diplom-Is, boosting cost-efficiency and flexibility.
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Kostrzyn, Poland.ICT is one of Europes leadingmanufacturers of paper handkerchiefs, householdand toilet tissue, paper towels and other hygieneand cosmetics products made from pulp. Sevenplants across the continent are responsible forproducing and processing these goods, includinga factory in Kostrzyn. The warehouse here was
operated manually and, as such, was not able tomeet all requirements. This meant additional ex-ternal storage facilities were needed. After care-ful consideration, the company decided to con-solidate activities at a single warehouse. As ICT
logistics head Dariusz Drzazga explains, The newwarehouse will help us deliver goods to customersfaster, more flexibly and more efficiently.
SSI Schaefer Giebelstadt was tasked with plan-ning and developing a turnkey warehouse solutionon a site of around 16,000 square metres. The
intralogistics expert was responsible for the end-to-end execution of the project. Implementationphases included a steel construction for a silo-design, automated high-bay warehouse, almosttwo kilometres of pallet conveyers, storage and
Speedy solution for paper towels
SSI Schaefer has installed a high-bay warehouse, innovative palletconveying technology and a reliable warehouse management systemfor hygiene tissue manufacturer Cartarie Tronchetti S.p.A (ICT),significantly improving efficiency and transparency.
Over 60,000 pallet positions
in a 36-metre-high, nine-aislehigh-bay warehouse.
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retrieval devices and corresponding control systems.SSI Schaefer also delivered warehouse managementsoftware, which provides a solid IT basis.
The automated, 36-metre high-bay warehouse is al-ready up and running. In addition, the outdoor storageareas have been closed and all inventory integratedinto the new system. The warehouse managementsolution controls and monitors all outgoing and in-coming goods, the dispatch area picking processesand disposal of production.
There are two feed-in positions for pallets which aretransported via conveyers to the high-bay warehouse.Pallets that do not meet norm specifications areautomatically identified via a dedicated detection sys-tem and assigned a new system pallet. The checkedpallets are then transferred on two redundant tracks
via a conveyer bridge to the high-bay warehouse ata height of around 5.5 metres.
The silo-design high-bay warehouse is the beatingheart of the new system. Around 60,000 pallet pos-itions are used to store approximately 500 differentitems. Moreover, it features single-deep and double-deep storage. New storage and retrieval devices trav-el across the shelves at speeds of up to 230 metresper minute. That means as many as 225 pallets canbe moved into position every hour.
Items are retrieved on the bottom level. The softwaretriggers assembly of the orders and the storage and
retrieval system begins picking the pallets, achievinga throughput of around 600 pallets per hour. Finally,the goods are transferred to a 2,450-square-metredispatch area via a pallet conveyer system.
Here, chain and accumulating conveyors, rotary,roll, and gravity roller-conveyors, as well as shuttlevehicles and pallet stacking and destacking devicesensure efficient internal goods flow. Before the finalstep, the pallets are transferred to three shuttle ve-hicles and distributed to 40 feeding tracks. Only thepallets that have been requested are released. Atotal of 460 pallets can be loaded onto the ramps in
the dispatch area every hour, enabling the simultan-eous loading of 15 trucks.
Thanks to the new solution, employees now havecomplete visibility into all items, which means max-imum inventory control. The results speak for them-selves: lower transport and warehouse costs, timesavings in order processing, increased quality, andefficient, flexible, end-to -end processes.
Pulp & paper
Nine storage and retrieval devices, each withtwo telescopic forks, move along the aislesat speeds of 230 metres per minute andwith a lifting speed of 70 metres per minute.
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Eindhoven, Netherlands.PACCAR Parts Europe, a major provider of high-quality truck and trailer parts,has opened a 26,000-square-metre distribution centre. The new logistics hub replaces PACCARs pre-vious warehouse in Eindhoven. SSI Schaefer was tasked with fitting out the new facility.
Around 12,000 items are processed for orders here every day. To this end, 65,000 different truckparts are stored on pallet racks with a capacity of over 30,000 positions. Oversized goods are stored
in cantilever racking systems. Moreover, a platform featuring a modular shelving system offers spacefor small parts, and around 100 live storage racks are deployed for fast-moving items. In addition,30,000 totes and 80,000 labels are used to organise the warehouse. During implementation of thisproject, SSI Schaefer used some 130 tonnes of steel for modular shelving units and 580 tonnes forthe pallet racks.
The logistics centre has been up and running since March 2013 and was completed three weeksahead of schedule. PACCAR Parts Europe now benefits from first-class delivery capability for replace-ment vehicle parts. Whats more, thanks to greater capacity and increased efficiency, the companyhas more scope to grow its own DAF Trucks division.
New distribution centre for
PACCAR Parts Europe
Efficient storage of car parts
Modular shelvingsystem for smallparts.
Three-level modularshelving system forcar parts.
Geel, Belgium. Autoparts De Jonghe has been selling vehicle componentsand other car-related products since 1980. The company stores new andused parts in a warehouse measuring 15,000 square metres that serves itsfour sites. SSI Schaefer has developed a new storage solution for De Jonghe,enabling the delivery of parts for all common makes of vehicle within just24 hours.
The intralogistics expert implemented an R 3000 modular storage system with a three-level platformdesign. This ensures greater space-efficiency at the existing warehouse and significantly boosts
capacity. Four steps at each side lead to the next level of the structure. The solution has a total of4,000 modular shelves for both light and heavy parts. Even items of varying shape and sizes such asbody panels and exhaust pipes can now be stowed away easily. Depending on their length, these typesof items are stored horizontally or vertically.
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Fulda, Germany.The atzert:weber group runs four car show-rooms and a maintenance workshop (Auto Sofort Service)in the German state of Hesse. On a site of 22,000 squaremetres, the Volkswagen centre in Fulda showcases a rangeof vehicles from the VW, Skoda and Audi marques. In May2013, atzert:weber opened a new Audi centre at the samelocation.
Both businesses operate in parallel, with sales and after-sales services for each brand kept entirely separate. TheVW centre is on the left and Audi on the right. A brand-new
semi-automated parts store on two levels located betweenthe facilities is at the heart of warehouse logistics oper-ations. This is designed to act as a link between the bodyshop and the paint centre, and the mechatronics and ser-vices departments. Special-purpose tools required for thevehicles remain in the workshops but have been reorga-nised based on the SSI Schaefer locator approach.
Locator storage systems on both levels and a multifunctional LogiMat storage lift ensure efficientprocesses. The parts are stored in modular shelving, cross-beam and mobile racking systems, as wellas in drawers. The LogiMat lift has 60 trays and is directly integrated with the other systems. It fulfilsa range of functions: for example, it serves as a link between the levels, with one service opening ateach level, and it acts as an interim storage area for picked items before they are retrieved.
As Philipp Atzert, CEO at atzert:weber groups VW centre explains: Because orders are pre-pickedand stored in the lift for our employees, we cut waiting times at the collection point. Its really smart.
SSI Schaefer delivered all equipment for the entire undertaking. The relocation of the warehouse wasperformed in stages as defined by a dedicated strategy developed by the intralogistics player. Thismeant the move could be completed in four days and during ongoing operations. This combinationof new systems reduces waiting times and distances by over 70 per cent and saves around50 per cent on space. The facility is currently used for around 5,500 parts but has capacity for up to7,000 positions.
LogiMat storage lift
breathes new life into
car showrooms
Beijing, China.SSI Schaefer has implemented a distribution centre forVolkswagen in Beijing. It is the first time a LogiMat storage lift has beendeployed in the country.
Usually Chinas automotive players leverage shelf systems. However,with the aim of improving space efficiency and increasing picking speedfor small parts, this customer opted for two storage lifts in combinationwith multiple shelving solutions.
The LogiMat lift saves up to 90 per cent of warehouse space in comparison to conventional shelf systems and deliversfast, ergonomic picking for small parts. As a result, picking speed at the VW distribution centre has increased between six-and ten-fold. Additional systems include a three-level modular shelving system, a pallet high-bay warehouse with around12,000 positions and a cantilever racking system for the storage of replacement parts.
The first LogiMat for Chinas
automotive sector
Together, the LogiMatstorage lift (3 metres x7 metres) and a two-level locator storagesystem streamlineprocesses.
The LogiMat storage lift requires up to 90 per centless space than a conventional shelving system.
Automotive
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Logistics service providers
Bremen, Germany.BLG Handelslogistik operatesone of Tchibos largest logistics centres. Now,online orders are to be handled here too. To pre-pare for this change, new processes were need-ed. BLG has invested 50 million euros in bringingits 92,000-square-metre warehouse up to speed,tasking SSI Schaefer in Graz, Austria with design-ing the new workflows.
A highlight of the project was a two -storey sortingbuilding complete with conveying technology andconnected to the other warehouses via a conveyerbridge. In addition, SSI Schaefer fitted out threeexisting stock warehouses and a storage facilityfor returned goods. Now, some 17 kilometres ofconveying systems, 20 tote interim storage areas(Schaefer Carousel System), 133 picking sta-tions, 14 live storage racks for boxes, 96 packingstations, pallet conveyer technology, totes andtote palletisers plus 42 telescopic belt conveyersensure efficient, flexible processes.
Online orders are picked and collected in special
bins and the goods for brick-and-mortar outlets
are placed in boxes or totes. To this end, itemsare conveyed directly to the picking stations lo-cated across two of the halls. Here, employeesremove the goods either from live storage racksusing a pick-by-light system or directly from thepallet. Monitors at these workstations displaythe type and quantity of products to be picked.Integrated weighing scales can detect pickingerrors immediately. The conveyers transfer the
totes from one station to the next until all ordershave been processed. If a load carrier is not largeenough for the order, additional load carriers areavailable next to the operator.
The full totes are then transported via the con-veying bridge to the sorting building. Here, up to13,500 totes can be held in an interim storagesystem which also compiles the orders. Next, em-ployees pack the online orders into boxes readyfor shipping. These are sent directly to the dis-patch area. The new warehouse solution has beenfully up and running since May 2013.
Mammoth undertaking during ongoing operations
BLG Handelslogistik is responsible for delivering goods to German retailer Tchibos high-
street stores. Now, the logistics company is taking over online orders too. To supportthis task, SSI Schaefer has enhanced the central warehouse in Bremen.
Employees prepareorders for shippingat 96 packingstations.
Source: BLG Handelslogistik
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Logistics service providers
Dubai, UAE. SSI Schaefer has implemented anew warehouse for INL, a provider of logisticsand supply-chain solutions in the Middle Eastand Africa. The new facility is located at DubaiWorld Central, an international passenger andfreight airport.
The team from SSI Schaefer deployed leading-edge technology during the implementation with excellent results. The project was executedin phases and during regular operations. ThePR 600 pallet racking system, manufactured in
Germany, was tailored to meet the customersspecific needs. A high level of customisation en-sures significantly greater flexibility compared tothe previous solution.
Each pallet bay has space for two pallets side byside and up to seven full pallets can be stored ontop of each other, in addition to the ground level.As a result, INL now has capacity for 32,400pallets, and plenty of space for future growth.The SSI Schaefer team did a great job and alldeadlines were met. Implementation was fastand simple. It is highly likely that well turn toSSI Schaefer for future projects, too, said Paul
Maycock, General Manager at INL in Dubai.
Dubai, UAE.Founded in Germany in 1890, Khne +Nagel is now a world-leading logistics provider. Itsservices range from sea and air freight, to road andrail transport, to contract logistics. The companyoperates in over 100 countries.
In its Dubai warehouse, Khne + Nagel has intro-duced euro and industrial pallets. The combina-tion of a narrow-aisle and wide-aisle pallet ware-house system has improved productivity andreduced costs. Whats more, SSI Schaefers solu-tion has increased storage capacity by around40 per cent compared to the companys previous
conventional pallet racking system. In addition,warehouse throughput, picking speed and prod-uct reliability have all improved with an error rateof almost zero.
Phased warehouse
implementation at
Dubai World Central
Optimised warehouse in Dubai
Pallet racking system with32,400 positions.
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Inside SSI Schaefer
The SSI Schaefer Group operates over 50 subsidiariesaround the world. To present its cutting-edge, end-to-endsolutions to customers and prospects, the company hasa number of showrooms. These rooms feature permanentexhibits and are the perfect backdrop for customer meet-ings, internal staff training or industry events. In the lastissue of update, we profiled our facilities in Germany, Aus-tria and Switzerland. This time, were focusing on two show-rooms in Singapore, SSI Schaefers Asian headquarters.
Republic Polytechnical School, SingaporeOpened:2013
Showroom space:150 m
Exhibits: A diverse range of conveying technology,S-Pemat, E-Pick, live storage system for packages,modular shelving units, totes.
Usage:The facility is designed to train students focus-ing on the supply chain.
Objective: Students receive insight into automatedand manual picking processes. In addition, a varietyof sorting and diversion mechanisms are on display.
Showrooms around the globe
SSI Schaefer in Asia
SSI Schaefer SingaporeOpened:2011
Showroom space:220 m
Exhibits: Conveying technology, a parallel picking system incombination with RF picking, pick-to-tote picking, RF picking,
pick-by-light with E-Pick, pick-by-light with Multilight, mobilepicking with pick-by-voice technology, live storage systemsfor packages, modular shelving units, totes, a mobile rackingsystem for pallets, the Schaefer Orbiter System, the LogiMat
storage lift.
Usage: Primarily for customer demonstrations and for internal
staff training with a focus on picking.
Objective: The showroom aims to underline that a tailoredsolution does not just consist of one product but of multiplecomponents intelligently combined to form a comprehensive,end-to-end answer to challenges.
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Inside SSI Schaefer
Neunkirchen, Germany.SSI Schaefer has opened its own research and testing labora-tory at its site in Neunkirchen. The facility will be used to ensure the shelf systems pro-duced here fully comply with all standards, norms and requirements (ISO, EN, SIN, FEM,etc.). To this end, diverse tests are performed to verify the resistance, strength andload-bearing capacity of products and to prevent toppling and falling. Project-specifictests are used to check the rigidity of totes deployed in live storage racks. The resultsof these experiments are leveraged for production optimisation.
Based on these stability, reliability and endurance tests, customers can rest assuredthat the products they receive comply with the highest quality and safety standards worldwide. A similar facility is currently under construction in Malaysia with comple-
tion slated for early 2014. Automated systems are put through their paces at theSSI Schaefer Technology Centre in Giebelstadt.
So what does
Salomon Automation do?
New research and testing facility
Friesach, Austria. A member of the Schaefer
Group since 2008, Salomon Automation excelsin IT. Alongside the development of logistics soft-ware WAMAS, the company is a one-stop providerof made-to-measure, end-to-end warehouse sys-tems from fully automated to manual solutions.Professionals at Salomon Automation supportcustomers for the entire product lifecycle, fromthe planning stages, to implementation, to ongo-ing maintenance.
Information focus areasSalomon Automations Friesach headquartersis the key site for WAMAS. Additional offices inGermany further strengthen the companys know-
ledge network.
The organisation not only focuses on logisticssoftware but also on process management.WAMAS was developed based on experience
gleaned from numerous projects around the
world. That means the software was not createdwith one particular customer in mind but can bedeployed universally to solve diverse challenges.Support and assistance during implementationare key parts of the process. And employees atSalomon Automation are experts when it comesto advising customers on intralogistics, alwaysensuring the right balance between hardware andsoftware. As a result, they can create the idealsolution for every requirement.
Corporate cultureIn 2012, the Friesach site was awarded the titleAustrias Best Employer. The philosophy behind
this is simple: a friendly, open atmosphere en-courages excellent teamwork. Training is anotherimportant aspect, with specially designed courseson software development, logistics and automa-tion technology regularly on offer to staff.
Salomon Automation, the
software specialist within theSSI Schaefer Group, is head-quartered in Friesach near theAustrian city of Graz.
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Inside SSI Schaefer
What significance do containers have for SSI Schaefer?
T. Schleisick:They are a cornerstone of our corporate history and areextremely important for us. However, over the years many more signifi-cant product areas have been added to our portfolio.
Are steel totes outdated in this day and age?
T. Jettkant:No, both plastic and steel totes serve their own particularpurpose. For some scenarios, steel is the only option for example, ifthe goods are very heavy or temperature sensitive, or additional modifi-cations or washing is required. Thats why we will continue to offer steeltotes. Without a doubt, though, plastic is more versatile and can cover
a broader range of applications. Plastic containers are lighter and canbe used in automated warehouses, for instance in automated smallparts stores, on conveyors, or in robot-controlled systems.
What is the role of your containers in automated systems?
T. Schleisick:Automated systems are generally designed to meet spe-cific customer needs. And that is also true of the containers. They needto fulfil complex requirements both in terms of protecting the goodsbeing stored or transported and being suitable for use in automatedlogistics processes. At the start of any project, the central questionfor us is How do I move the customers products as efficiently, reliablyand safely as possible within the system? Based on the results of thisanalysis, we develop the ideal container concept for that company often working closely with the customer.
What can you tell us about the current market situation?
T. Jettkant:At the moment, were seeing a rising demand for tailor-madesolutions. And this customisation trend applies to all industries. Typicalchallenges we face include automating containers and ensuring theycan be both managed internally and tracked externally, for example viabarcode, 2D code, RFID transponders or in-mould labelling. Another keyissue is the protective nature of the container: it needs to keep dustand moisture away from the products. The demand for perfectly tailoredtransport containers increases when youre handling very sensitivegoods. After all, the container is closest to the product so it is worthinvesting in the ideal packaging solution.
SSI Schaefer containers have been around a longtime. And they are found in production facilities andwarehouses around the world. Thomas Schleisickand Thomas Jettkant from SSI Schaefer shed light
on this key element of the industry.
Thomas Schleisick, Head ofSales, Container Systems.
Thomas Jettkant, Head ofSales, Bespoke Packaging.
Containers in
the spotlight
Automated containers for ever-morecomplex projects.
Fabricated inserts are theperfect fit, protecting goods
during transit and in automatedhandling systems.
Market launch of euro-standardtotes in the 1970s.
A milestone in companyhistory: steel totes.
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About updatePublished by (responsible for content): SSI SCHFER / FRITZ SCHFER GMBH 57289 Neunkirchen/GermanyPublic relations / editorial team: Jochen Besser e-mail: [email protected]
Software for more efficientwarehouse processes
Whether manual or automated warehouse systems WAMASmanages, monitors and optimises logistics processes fromend to end.
As an SAP service partner, we support you with the implemen-tation of SAP EWP solutions tailored to your needs, and delivercomprehensive after-sales services.
SSI SCHFERFRITZ Schfer GMBH
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SSI SCHFER NOELL GMBHi_Park Klingholz 18 -19
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