SSI SCHÄFER News

SYSTEM RETROFIT PROJECTS FOR BUSINESS

Mon, 28 Nov 2011 08:33:00 +0100

Automation and modern intra-logistics solutions increase the productivity and efficiency of a warehouse. Rapidly changing product offerings, more orders with smaller lot sizes plus significantly increased demand for flexibility combine to require new and more efficient systems and holistic solutions for faster, cost-effective access to the goods.However, the "optimum solution" is not always necessary or possible. System modernization or expansion, so-called retrofitting, is often an alternative. By modernizing systems and system components the operational safety is not only increased, but also results in improved warehouse availability and a reduction in personnel costs of up to 30 percent. Intelligent resource management and green logistics offer further potentials. Based on these parameters, retrofit projects become more and more important. Significant aspect: updating the IT-environment and drive and control engineering.SSI Schäfer responded to this development in the early stages by forming a specialized group. Using their business strategies, warehouse and production systems can be updated quickly and safely to the latest state of the art technology by exchanging components, expanding or modernizing IT, and adding new material flows which can be optimally linked to existing production systems. This applies to old systems from SSI Schäfer as well as to systems from third parties.During the last few years, SSI Schäfer has completed a two-digit number of retrofit-projects every year. Key to these projects: For the most part, old systems are in operation where failures would lead to a negative business outcome. In addition, the time frames for the reorganization are shorter. And: Existing and often restrictive building structures have to be considered during the planning phase for the future logistics concept. Meeting schedules, flexibility and expertise regarding business specific processes and available technologies are therefore required from the plant engineer.These requirements are fulfilled by SSI Schäfer with an extensive service offer. First, the necessary requirement for retrofit-measures is determined by specialists from SSI Schäfer. When planning the new intra-logistics concept, the focus is on the mechanical and electrical optimization of the system and the processes, taking into consideration optimal space utilization and/or creating free space. Ultimate goal: optimization and transparency of material flow, sizing the load carriers to be used, as well as work station design - consideration of safety concepts following new machine guidelines. With the customer, a schedule for implementation is prepared, with as little impact on production as possible. SSI Schäfer recently exchanged the entire tray conveyor system, including drive and control engineering for the storage and retrieval machines at KHS in Dortmund, in ten weekends.When modernizing or integrating dynamic system components, special emphasis is placed on the integration of e.g. energy-efficient drives. This ranges from efficiency-optimized drive versions and the so-called deadweight balance via an intelligent control of SRM-main axles including power recovery devices as well as scheduling shutdowns. Old drives and converters are replaced by modern, energy-saving and powerful aggregates, the controls are modified to Siemens S7 and the communication to TCP/IP-protocols.Orders are currently in progress for logistics providers such as Geodis or Plastal in Hambach. Replacement of the existing warehouse management system with the SSI Schäfer software "ant" was successfully completed in the last few months for SKF, Berlin. The existing order-picking workstations and computer hardware were also modernized and updated at this project.Last but not least - the topic maintenance and availability. The newly installed components not only increase the efficiency and throughput by improving networking of the single controls, but in fact the new systems are significantly lower-maintenance and generally offer better and faster remote maintenance possibilities.The example of brand manufacturer Braun located in Marktheidenfeld indicates that such projects can be planned and implemented with SSI Schäfer. The continuous modernization of a nine-aisle high-bay warehouse was coordinated and implemented with the customer over several years. At this point, the components are state-of-the-art and the 1982 system has subsequently received a CE-certificate.These examples confirm: retrofitting is often a good alternative compared to the high investment for constructing a new system. Companies who regularly modernize always receive state-of-the-art systems - and benefit of the economics of the system. The first priority for all parameters is: "As much optimization as possible, as little disturbance of daily operations as necessary“. The result is a single integrated solution. The high availability and the extended life span of the modernized production system also offers good protection for the investment.

Economically and ecologically effective

Mon, 14 Nov 2011 08:16:00 +0100

Sustainability is currently one of the most important aspects of logistics. Construction services and plant engineering experts, as well as logistic systems operators agree that the rapid development of information technology, including material and system development, primarily in the intra-logistics sector, offer excellent prospects for achieving a balance between economy and ecology. Green Logistics is the keyword that links intra-logistics with the economy and/or process safety via cutbacks such as optimizing time, space, employee, energy and materials-utilization. This requirement for resource efficiency applies during implementation of new systems as well as during retrofits, and/or the modernization of system and plant components. The 2010 intra-logistics forum organized by SSI Schäfer, Giebelstadt at the end of September spelled out the options of the plant engineers and operators in the disputed area between economy and ecology. The introduction of various projects and presentations regarding new developments were part of this forum. Users as well as experts of the Fraunhofer Institute presented practical examples, the latest trends and innovative solutions. More than 170 representatives from 89 companies and 27 countries used this event to exchange information presenting proven solutions and the latest technological developments. The focus: increase added value using aspects of effective Green Logistics….with striking results.Gerhard Lohmeiter, environmental consultant at Hellmann Worldwide Logistics, presented real-time initiatives of the company implementing the requirements of Green Logistics. Logistics service provider Hellmann is specifically concentrating on the reduction, respectively neutralization of CO2-emissions ocurring during transport, storage and commissioning. Sample calculations indicated how the daily CO2-emissions can be reduced by around 50,000 kilograms by relocating 300 swap trailers from the street to the train. Hellmann used different route planning and emission calculation tools for that.In addition to the transport carriers and the introduction of CO2-neutral transports, Hellmann targeted the processes of the entire value added chain - especially their energy consumption. The steps taken range from the utilization of regenreative energies via subsequent utilization of energy-efficient lamps including insulation of the buildings. Hellmann identified the utilization of energy-efficient conveyor and lifting technologies as another important goal.For conveyor and lifting technology particularly significant progress has been made in the last few years using plant engineering regarding resource efficiency. SSI Schäfer summarized one topic titled „Green Crane Technology“. Following consistent improvements in the mechanics using measures such as effectiveness-optimized drives, lightweight construction and rolling resistance-low material combinations between wheel and rail, possible energy savings are decisive for the new and future developments of the systems. Up to 50 percent of the energy consumption can be reduced by the integration of power recovery systems - depending on superior system and order structures. Resulting in an ROI for modern technology utilization of less than three years. The same applies to the models of a wear reducing, low-load operation (20 percent saving, ROI less than 1 year), the DC-link connections (12 %, < 1 year), an intelligent drive cycle control (8 %, < 1 year) or energy-efficient, efficiency-optimized drives (4-8 %, 8-15 years).The more these approaches are used, the larger the possible savings. This is documented for a small parts storage and retrieval system (MiniLoad) with draft cycles using a comparative calculation presented on the Intra-logistics forum in Giebelstadt. The energy consumption is reduced when using a power recovery system from around 71 Watt/h to around 54 Watt/h. Using a power recovery system in combination with a low-load operation or using a power recovery system with low-load operation and intelligent driving cycle control reduces the energy consumption up to 45 Watt/h – resulting in an energy savings of more than 35 percent. An SSI Schäfer system using the latest developments which are based on intelligent drive cycle controls with axis-overall energy exchange instead of refeed, already available in the standard version, result in possible savings between 20 and 25 percent.Similar results can be achieved when utilizing energy-efficient motors in the conveyor system. Here, especially developed drive synchronous motors are characterized by highest energy efficiency (efficiency class 4). As innovator and leading plant manufacturer, SSI Schäfer faces the responsibility for implementing comprehensive resource efficiency in intra-logistics, especially for conveyor systems and in the development of new systems. This begins with planning and layout and ranges from efficiency-optimized drives to actual consumption points to stressing awareness for responsible power consumption.Economy and ecology do not have to be in conflict with each other. This is supported by examples where up to 50 percent energy savings are possible with longitudinal and lateral transports using modern conveyor systems compared to conventional systems. These energy savings can be achieved with careful system planning focused on energy efficiency. Other aspects such as pallet lifters with counter-weights using the load weight when lowered, on-site reduced stand-by-consumption or the energy-saving process optimization using parallel storage and retrieval certainly contribute to that.Effective, value added processes in intra-logistics are the main focus of development work at SSI Schäfer. This is done with the awareness that avoiding waste and the installation of efficient processes can increase the competitive capability which meets the requirements of „Green Logistics“. However: Useless resource consumption has to first be identified as useless. Efficiency loss from overstocking and stockout, multiple handling of items, insufficient warehouse and commissioning strategies, missing replenishment processes, time-consuming voucher systems and lacking transparency are often identified too late. The requirements for intra-logistics increase parallel, especially regarding performance, flexibility, on-demand-reaction, ergonomics and environmental compatibility.In fact, dynamic systems from SSI Schäfer such as the Schäfer Carousel System (SCS), the SQS, the Schäfer Case Picking (SCP) or the mobile racking systems are the most important components for the design of system solutions incorporating ecologic aspects of profitable land and building utilization. Combined with a high-performance Warehouse Management System (WMS) the processes can be designed both inhouse and company-wide under the aspects of sustainability - for example by optimization of the loading order or design of multimodal transports.Stephan Stucky from the Swiss logistics provider Coop clarified during the Intra-Logistics Forum which capabilities for resource efficiency can already be developed using the correct commissioning process. Coop controls the processes in 16 regional and national distribution centers with SSI Schäfer’s IT-systems, SSI Schäfer WAMAS and SAP as the superimposed system. Controlled by the WMS-system WAMAS it is commissioned, in addition to the main procedure, with Pick-by-Voice with a forklift terminal (whole pallets), manual terminals (small amounts) and Pick-by-Light (deep-freeze area). This results in flexible, transparent processes with optimum efficiency, respective savings, of the existing resources. The implementation of the high-performance and homogeneous logistics system of SSI Schäfer led to a significant decrease of process interface and reduction in complexity at the reference Valora project as presented by Stefan Gächter (area manager logistics Valora). In addition to the standardization and safety of processes, Valora can show a reduction of logistics costs of 14 percent.Efficiency and responsible handling with available resources do not have to contradict. This is demonstrated using the examples as well as by the presentations and reports from the Intra-logistics forum. Beginning with the construction planning concept integrating high-quality, environmental building materials which reduce energy demand via the Green Crane Technology to modern dynamic systems and ergonomically designed work stations, SSI Schäfer has an extensive product portfolio which is similarly designed for resource efficiency and economy.The newest products which will be presented to trade experts at CeMAT 2011 prove that SSI Schäfer is not yet satisfied with their results. The resource efficiency is apparent from all systems and components. New material flow systems such as the Schäfer AutoCruiser save up to 80 percent energy compared to conventional systems. Even more: SSI Schäfer as innovation leader is continuously involved in numerous research projects. Results directly influence product development. Newest example: cooperation in energy-efficiency studies for small-parts storage and retrieval machines at the institute for logistics and material flow engineering at theUniversity Magdeburg. These studies deal with recording energy consumption and recovery for drive axles. SSI Schäfer as research partner provides a one-aisle warehouse with a Schäfer Miniload Crane (SMC) and supports the analysis, data evaluation and their integration into new developments.If the challenges of sustainable, environmental logistics are subsequently integrated in the development of innovative solutions, proccess optimization for resource efficiency, and the implementation of Green Logistics, they can then be economically combined with each other. With its range of products and services, SSI Schäfer covers the entire spectrum. In the future, SSI Schäfer will continue to play a significant role in the research and development of new technologies and information systems that further the implementation of Green Logistics and sustainability. Resulting innovations will provide companies with considerable room for improvement in their in-house value added chain, especially in intra-logistics. Concerning intra-logistics, this became apparent during the Intra-logistics forum 2010 in Giebelstadt. The high standards of Green Logistics can be aligned with economic requirements of modern business strategies. Investments that are well worth it. It is up to corporate decision makes to utilize these options.

Seamless, future-oriented solution

Fri, 28 Oct 2011 08:04:00 +0200

Among beer connoisseurs, the original Budweiser lager from the Budweiser Budvar Brewery in the Czech Republic is one of the world's best beers. Brewing history has been made in the town of České Budějovice since 1265. And, since the end of the 19th century, these delicacies originated in the Czech Joint Stock Brewery, which subsequently became the Budweiser Budvar brewery. The brewery now produces around 1.3 million hectolitres of beer each year. Almost half of the production is exported to around 50 countries on every continent. In Germany alone, over 200,000 hectolitres of Budweiser Budvar beer are sold – and the trend is on the up-swing. As a result, bottling production lines and internal logistics in Budvar have been continuously modernised since 2005. The most recent development: a 26 metre high-bay racking system. In three aisles, 3000 pallet storage locations are available for pallets with a weight of up to 900 kilograms which are directly connected to production. The contract to implement the project, including the logistics concept, roof and wall construction, steel framework and pallet conveyor technology, was awarded as part of a bid process to intra-logistics specialist SSI Schaefer, Giebelstadt, as the general contractor. "We were looking for a solution that met our complex requirements using the latest technology", explains Pavel Panek, Head of Logistics and Purchasing at the Budvar brewery. "The key objectives included maximum utilization of existing limited space, 100 percent process control, real-time tracking and the integration of our RFID-led block warehouse into the new Warehouse Management System which is integrated with existing ERP system. SSI Schaefer offered the best concept to meet these needs with an attractive price/performance ratio."Assembly work on the warehouse construction was started in March 2009. The work was completed in less than 20 weeks, including technology and sheathing. The warehouse went into operation with the first incoming pallets in August 2009, as scheduled. The new plant has been running at full operation since the end of September 2009. Up to 50 HGVs are loaded at the outgoing goods gates of the new Budweiser logistics centre each day to send the precious brew on its way to over 50 countries around the world. "This is achieved without any problems due to the transparent goods flow, the additional capacity and fast throughput using the plant technology", confirms Panek.However: "The high bay racking system demanded a little creativity even during the basic planning stage", reflects SSI Sales Executive Jan Rindt. "Firstly, the spatial specifications were critical, and secondly, the goods flow and the storage space management of existing warehouse structures had to be integrated." Together with the brewery, the necessary warehouse capacity was defined and an appropriate layout created. "With the specified height of 26 metres for storing 3000 pallets of finished products, a building with a conventional steel or steel/concrete hall construction was quickly dismissed due to time restrictions, engineering and financial reasons", explains Rindt. Instead, work began on a silo design high bay racking system almost six metres below ground level. In terms of statics, the self-supporting racking also forms the basis for securing the external shell and the roof.When selecting the materials for the high bay racking system, special precautions against excessive heat buildup and against the effects of frost needed to be taken into consideration including fire protection criteria. Sandwich panels with high insulation properties and a high fire protection rating, as well as heat-dissipation flaps installed on the roof ensure that required thermal conditions are met.A further spatial consideration: Lengthwise in front of the high bay warehouse there is a large consolidation and preparation area. This restricted the number of warehouse aisles in the high bay warehouse. To achieve the required number of storage positions in the three-aisle warehouse, and to fully utilise the existing, available space, the first row of shelves and the storage and retrieval devices in the first aisle were designed for double-depth storage. Single-depth storage is provided in the two other racking aisles, "this means we quickly have direct access to the single pallets needed", confirms Head of Logistics Panek.The materials flow:The beer crates or cartons stacked on 120 x 80 cm pallets in production using palletizing robots pass through the high bay warehouse via roller track and conveyor belt technology to the transfer station. Around ten metres above the warehouse ground level, the contours and weights of the goods are recorded, and entered into the Warehouse Management System installed by SSI Schaefer. Controlled by WMS (storage location assignment) and control technology (conveyor technology drives), the pallets are then conveyed to a pallet lift. The remaining processes are controlled by the WMS. The lift transfers the pallets either directly to an outgoing goods table in the direction of the block warehouse or onto a transfer table into the high bay racking storage and retrieval devices. A transfer station has been set up for inside storage into the high bay racking system. A rotary table ensures that the pallets are aligned correctly. For pallets with stackable goods that need to be buffered in approximately 4000 storage spaces from the previous stock of the existing block warehouse, information technicians needed to deploy all their skill and cunning. "At the start of the project, Budweiser decided to apply the principles and strategies for controlling the automatic high bay racking system in the existing block warehouse as well", explains SSI Sales Executive Rindt. "A key feature was that the warehouse processes in the block warehouse are processed via Radio Frequency Identification (RFID). As a result, inventory management and process control functions needed to be integrated into the new WMS both for the automated high bay racking system and for the manually operated block warehouse equipped with RFID."To accelerate the inward and outward storage processes in the block warehouse, Budweiser places considerable emphasis on avoiding unnecessary delays via storage space scanning and confirmation sequences. “Therefore we have decided to use RFID not in connection with product but in connection with storage location” accents Panek. All warehouse channels in the block warehouse are therefore identified using RFID tags. In addition, RFID tags are also fitted to all transfer stations on the conveyor system. Display is used to assign the jobs to the fork lifts from the WMS. The fork lifts are equipped with RFID aerials. When a fork lift drives into the storage channel, the fork lift information is automatically captured and read by a reader. The job information stored on the WMS also defines whether the fork lift carries out inward or outward movements, and in what volume. "The liquids in the environment itself can represent a challenge for the RFID", says Rindt. "What is more, the different technologies and control processes need to be programmed into the WMS."The result is "a highly efficient Warehouse Management System that takes the features and parameters of the individual storage zones into account and unites the warehouse system to create a compact unit", explains Head of Logistics Panek. A comprehensive overview of the utilisation level of the system and resources is also provided using a visualisation system installed by SSI Schaefer.For order picking, the WMS initiates the outward storage processes in the high bay racking system and in the block warehouse. With its speed of 130 metres per minute and a lift of 54 metres per minute, the storage and retrieval devices achieve a throughput of up to 100 two-way movements per hour. The outgoing pallets pass via the installed conveyor technology with roller tracks, chain conveyors and corner switchers to the acceptance station for the fork lifts that are connected directly to the high bay racking. At the same time, the RFID-aided order picking processes are carried out in the block warehouse. In the preparation area in front of the high bay racking system, the jobs are then compiled and prepared for dispatch."A seamless and compact, future-oriented solution", summarises Panek. "As part of a rapidly and reliably implemented project – in terms of the complexity of the task – SSI Schaefer designed an intralogistics concept for our processes that provides maximum warehouse capacity and throughput with maximum space utilisation. The integrated process control has also resulted in the minimisation of order picking errors. Our objectives have been realised in full."And there's more. The system is designed so that Budweiser Budvar will not have any problems in the future integrating further changes to business processes into the plant. For example, a rail connection is already being planned. In the medium-term, the conveyor technology leading into the block warehouse and high bay racking system that is currently used to convey 120 x 80 cm pallets only will be re-designed to transport the larger industrial 120 x 100 cm pallets. "This will require external guidance of the pallets", explains SSI Sales Executive Rindt. "Thanks to the modular design of our components we will then be able to retrofit our systems at the appropriate time without any significant downtime for Budweiser."

Automated Dual Purpose Picking and Storage System for Republic

Wed, 26 Oct 2011 17:45:00 +0200

Having already established a solid working relationship with SSI Schaefer in the Far East, IDS (Integrated Distribution Services) Logistics, an Asian-based third party logistics provider looking to expand its foothold in the UK, called upon preferred supplier SSI Schaefer to install an integrated picking and storage system to manage the storage, picking and distribution of flat-packed garments for Republic. With 120 stores currently on the high street, Republic is set to rapidly grow to more than 200 stores over the next two to three years raising its high street presence with additional plans to capitalise on e-commerce sales thereby increasing its online market share. Adrian Robinson, Logistics Director, IDS, said: “We needed SSI Schaefer to design a new system that would handle Republic’s retail store consignments and fulfill its online shopping orders with ease – a challenge more than accomplished with the automated dual purpose picking and storage system now in operation.”He continued: “The installation has enabled us to drop a shift – previously we worked two, sometimes three shifts – we now work one full shift with extra hours to handle late order e-commerce shipments. Currently running at just half its capacity in order to achieve the revised shift pattern, the system has significantly increased picking and shipping accuracy. We are extremely pleased with how the system is operating.”The system is made up of low-level adjustable pallet racking, incorporating shelving for carton picking and pallets for bulk storage. An extensive conveyor system, with a re-circulating facility, routes and delivers cartons of product to a series of ‘put to store’ zones, where items are then individually picked and sorted to store delivery totes.The dual system is effective because full carton volumes of product are picked and supplied for sortation and distribution in specific quantities to stores and residual items are passed automatically via the conveyor to supply or replenish separate e-commerce picking locations without having to be returned to stock. A ‘carton-live’ tote buffer accumulates full totes before being palletised for shipment to stores.Either side of the conveyor system sits an extensive wire basket-based storage facility providing more than 10,000 locations which hold stock for zone-picking internet orders into totes before they are individually packed into bags or cartons for onward delivery. Every product is identified using barcode scanners at both case and individual item level ensuring the whole operation runs at optimum order picking and delivery accuracy.

Efficient processes for motorbike accessories

Mon, 17 Oct 2011 07:42:00 +0200

By offering everything bikers could possibly need, the LeMans Corporation has become a leading retailer of motorbike parts, accessories and clothing on the US market. From this base, the senior management started thinking about expanding into the European market. The company's European subsidiary, Parts Europe, chose Konz near Trier (Germany) as the location for its new central warehouse. In the winter of 2008, the foundations for a modern warehousing facility were laid in a green field near the town. The first of four project phases is already complete. Once phase 4 is finished, the entire warehouse will cover 45 000 m².During planning, the management had to take into account the different market structures and requirements in Europe and the US and consider the different intralogistics processes. Since there are different items for everything from tyres and small parts to protective gear, the company needed a totally new approach and a compact installation, mainly automated processes, efficient software and order-picking strategies different from those deployed in the US.SSI Schaefer was tasked with the job of planning the intralogistics concept and providing the necessary equipment. Not only did the companies from the SSI Schaefer group deliver an impressive steel construction, innovative conveyor technology and installation of proven IT systems, they also demonstrated their ability to deliver a coordinated project without conflicts at interfaces. Parts Europe describes their involvement as "a reliable partnership of mutual trust throughout the course of the project resulting in an ultramodern installation, tailored to our needs, giving us a base for solid growth in Europe".The distributor has now firmly broken into the European market. The European central Parts Europe warehouse has been operational since the start of March 2010. Over the next few years, more than 10 000 customers, from anywhere between the Atlantic und the Urals, the North Cape and the Middle East, will receive their orders from Konz in between 24 and 48 hours. To this end, the Parts Europe warehouse holds 150 000 items in stock from many different manufactures and can order-pick up to 2500 shipments an hour. Parts Europe is still new to the market and is expecting order processing to peak in the spring when bikers spruce up their bikes for the new season. Further growth is therefore expected and Parts Europe is planning to process up to 20 000 shipments a day in this DC over the next few years.The intralogistics installation design and components had to be tailored to this forecasted increase in orders and the heterogeneous range of items. In response, the intralogistics specialist developed a complex installation concept with transparent goods flows and individually customised, automated processes for the 16 500 m² warehouse. These processes are controlled by the WAMAS warehouse management system (WMS) and the Convey warehouse control tool from SSI Schaefer. "Given the complex tasks, processes and material flows, the project software was a real challenge," says Hannes Schuster, project manager from SSI Schaefer, Graz. "We had to use the software to develop one solution harmonised to all organisational requirements."Currently the Parts Europe warehouse is split into four areas: tyres store, small parts store, full-case/self-ship area and hazardous goods store. Quarantined goods are also held in a separate area. Deliveries are recorded and split up using WAMAS. Once the barcodes have been recorded, all the items' information is available for use. What is known as a "dimensioner" is used to record the mass, quantities and weight of every new product. This data is linked to the product barcode and stored in the WMS. Not only does this give Parts Europe totally accurate data about the items in its warehouse, but by using supplier barcodes, it avoids the inconvenience of having to re-label.The recorded items are passed on to the conveyor system. It transports the items to the storage locations in the various warehouse areas defined by the WMS. "In total SSI Schaefer has installed around 800 square metres of self-supporting steel platforms for the conveyor technology, sorters and packaging machines installed," explains Schuster. "All in all, the installation comprises 4 kilometres of conveyor technology. More than 800 tons of steel has gone into the shelving and platforms."Four material flows are in place taking items into storage:The order-picking warehouse for small parts is a four-storey platform system with an integrated hanging garments store for biker clothing. Each racking bay has 18 storage levels. A total of 16 000 storage locations are provided in the 2200 m² of order-picking aisles covering four storeys.The second key element is the tyres store. Tyres are supplied loose in containers and separated on telescopic conveyors with an overhead conveyor system and what are known as J hooks. The tyres are suspended from the hooks, the barcode recorded and they are then stored by the overhead conveyor in a 10 m high platform system covering three storeys. There is a total area of more than 3100 m² for tyre storage, providing twelve storage levels per racking bay – 6720 storage levels in total. The final stage of the process involves recording the location and tyre barcodes with handheld terminals and posting the items in the WMS. One special feature of the steel construction is that in order to prevent pressure points on the tyres, the storage level cross bars are welded on at angles. This means that the tyres make even more contact with the surrounding framework and are not forced in.Pallets of items in their original packaging, which are shipped to the motorbike retailers in this form, are transported to the full-case/self-ship area by forklift. There are around 1900 pallet storage spaces. A separate, single-storey R 3000 modular shelving system is provided to store hazardous goods such as paints, batteries and oils, in a separate hazardous goods store. The shelf storage locations with mesh bases and drip trays allow liquids hazardous to water to be stored in compliance with statutory requirements. The option of adding another storey to this system if required was also taken into account during the design.However, the special features of the installation design, material flow concept and software only become apparent during order picking and when assembling orders. Numerous redundant safety features, an intelligent material flow concept and innovative case calculation ensure maximum efficiency and reliable order processing. According to Schuster, this is all thanks to "a conveyor system which can transport the entire heterogeneous range of order-picked items and IT with an intelligent range of functions."Order picking is initiated by the WMS. In the tyres store, the process uses a second overhead conveyor circuit. In order to minimise the number of access aisles, the WMS combines various orders for picking depending on where the tyres are stored. The sequence for picking by order is defined during subsequent order consolidation. Order-pickers receive the orders via radio scanners. The order-picked tyres are hung onto the overhead conveyor's T-hooks and the barcode is scanned. Picked orders are checked automatically at the end of the respective storey before passing on to the next one. There are several possible variants for tyre shipment: individual tyres without packaging or in boxes, several tyres bundled or in boxes and tyres plus small parts in a box. Mention should be made of the fact that when orders are transferred, the WMS from SSI Schaefer uses the dimensions and weights stored in the system to automatically determine the most favourable packaging unit and volume- and shipment-optimised combination of picked order items. If the WMS calculations indicate that tyres are to be combined with other items to form a shipment, they are transferred to the consolidation area.Small parts are picked straight into shipment boxes in the four-storey platform system using radio scanners. Following a volume calculation, the WMS defines which of the six box sizes to use. The boxes are arranged automatically and provided with barcode labels. The WMS requests order-picking in containers for small parts which form part of tyre shipment orders. SSI Schaefer has provided 600 dividable standard containers for this purpose. One continuous conveyor line transports the boxes and containers from one order-picking area to the next. Integrated weighing systems are used to check the picked items before they move to a new storey. Any incorrect order picking can therefore be corrected immediately to ensure a high level of order accuracy. Following order picking, the boxes and containers enter a loop. This discharges the load carriers, either towards shipping preparation or – if combining with other order items – to a consolidation station. "One of the special features of the installation design is that all items are transported on the same conveyor system," says Schuster. "This makes optimum use of space and allows orders to be specifically consolidated at various workstations."The conveyor system uses sequencing roundabouts to transport the containers and tyres to one of six consolidation stations as appropriate for the order. The Convey warehouse control tool from SSI ensures appropriate sequencing. At the consolidation stations the small parts are repackaged into the tyre boxes. Wherever possible, staff also fill the spaces around and inside the tyres to ensure volume-optimised shipment. After final weighing, Schaefer Compact Insertion provides all order-picked boxes ready for shipment with the corresponding papers. Another station places lids on the boxes, provides shipping labels and if necessary uses a strapping machine to wrap the box. This part of the installation greatly helps to minimise shipping costs. The shipment is then passed to a cross belt sorter where all order items from the tyre and full-case stores, small parts and quarantined goods areas are brought together. The items are discharged to the respective shipment tracks of five shipment stations where the orders are stacked onto pallets or transferred to a telescopic conveyor.Speed and reliability are key factors to the success of retailers in the B2B segment. The quality of delivery capability and order processing determines a company’s future competitive position. The intralogistics solution which SSI Schaefer has produced for the European central warehouse makes Parts Europe even more efficient than the company's warehouses in the US. Incoming goods recording using supplier codes, pick-to-box order picking in shipment boxes, volume optimisation for shipment volumes and a conveyor system which can be left to run whenever and wherever it is needed have all helped Parts Europe focus on efficiency upon entering the new market - thanks to the SSI Schaefer solution. Positive results confirm that this was the right decision - a solid basis for future growth.

Sophisticated Order Picking for Coop Danmark A/S

Thu, 26 May 2011 13:47:00 +0200

Wanting to exceed in both customer delivery and reaction times, Coop Danmark A/S recently reconfigured its logistics to provide an optimum, intelligent storage and distribution system using the latest technology. Bringing together seven regional warehouses into one central warehouse in Odense, Denmark, equipped with state-of-the-art order picking processes, was no easy task - after an international invitation to tender, the contract was awarded to SSI Schaefer."In view of our diverse product range, we were looking for a solution with intelligent material flow and well-defined order picking strategies", said John Møller, Warehouse Manager at Coop. He continued: "SSI Schaefer offered the best solution for our requirements along with an ideal price/performance ratio".The three-block high bay warehouse (HBW), which now serves as a supply and transfer warehouse, has four aisles per block with over 36,000 storage locations for single-deep storage of pallets that can weigh up to 1000 kilograms each. Twelve storage and retrieval machines, that move at a speed of up to 250 metres per minute, ensure quick storage and retrieval of more than 500 pallets per hour. Running alongside the high bay warehouse is the WMS that controls the manual low-bay warehouse, storing positions for man-to-goods order picking of fast-moving items, available across three shelf levels. "Stock and processes at the warehouse in Odense are governed according to advertising campaigns", explained Peter Lambrecht, Project Manager for SSI Schaefer. "The objective is to achieve a high throughput in a short time, taking into account finishing treatments. Due to complex product lines, different types of storage areas in addition to several different order picking strategies, characterise the flow of goods at Coop’s logistics centre."Items delivered on pallets are logged in goods receiving and transferred to the high bay warehouse or block storage. Articles, which for example will have CDs added, are allocated to workstations immediately and then stored in the high bay warehouse as a new stock item. Smaller, high-value items are stored in a separate paternoster system. Order picking shelves with an attached gravity-roller-conveyor are installed for small volume commodities that are not large enough to be picked directly from the pallet. Both systems are supplied from the high bay warehouse or the manual warehouse – depending on the advertising campaign. "Supply of order picking positions and the picking process itself are controlled by the WMS", said Lambrecht. "Due to the varied order picking strategies, this project was a special challenge for our IT department."Up to 25,000 order lines for just under 600 orders are processed daily – five partially linked order picking strategies are designated for this task. Each HBW block is equipped with a picking station to palletise items for large orders.Controlled by the WMS, source pallets are retrieved from the high bay warehouse and allocated for order picking at six source positions in each block. There, supported by height adjustable, ergonomically designed working platforms, items are picked from the source pallets onto seven target pallets. Partially used and pre-picked pallets are stored in the high bay warehouse again; empty pallets are removed automatically. Readily picked target pallets are transferred to consolidation points. If commissioned work is complete and automatic load secured, they are forwarded directly to the three dispatch areas via the conveyor and lift systems. In addition, the WMS arranges for the disposal of packaging waste which is collected in lattice boxes and removed by forklifts."Due to the high portion of smaller consignments (approximately 30 percent) that have to be picked in order commissioning, we followed the recommendation of SSI Schaefer and created a separate picking area for this range of articles", said Møller. For this purpose, a three-level flow rack with a total of 120 channels for up to five bins each was installed and connected to the pick positions for larger consignments. The facility is also equipped with a Pick-by-Light-System. Items from pallets are picked into boxes or bins made available on trolleys – up to 12 storage aids per trolley. After a container has been filled or one product group completed, the order picker generates a label for each box – these are then temporarily stored in the channels of the shelf system."Once picking for a specific shop in the large consignment area is complete and this same order also requires goods of a pre-picked product group, a box from the shelf-channels is added to the shipping pallet”, said Møller. While being transported on the conveyor system, ready-picked pallets pass through a wrapping station and transferred to the consolidating or dispatch area via the lift system. "Apart from a high picking-rate and a low error rate the advantage of this concept lies in the improved shipping package and safety for items as well as the preventive theft protection after the handover of goods", continued Møller. In the consolidation area, pallets from the large dispatch area are consolidated with pre-picked or whole pallets from the high bay warehouse as well as with picked items of the manually operated storage areas to complete the order. "Utilisation of space, high flexibility and reliable order processing - SSI Schaefer has designed a very efficient solution. Not only has it increased our throughput and process reliability but offers us the capacity for future expansion”, summarised Møller.

Teva gets Automated

Tue, 18 Jan 2011 08:27:00 +0100

SSI Schaefer has enabled Teva UK Limited to significantly increase storage capacity, improve picking performance and sharpen efficiency and customer service levels all whilst reducing labour overheads within its new distribution operation. The design and build of a new automated distribution centre in Castleford, West Yorkshire, was key to achieving such impressive results, handling not only immediate storage and distribution needs but also accommodating future growth of the business. Teva, part of one of the top 20 pharmaceutical companies in the world and the UK’s leading generic manufacturer of pharmaceutical goods despatching over four million items per day, continually evaluate service and products offerings to ensure the company’s continued success rates. Working closely with Teva, SSI Schaefer designed and installed the internal layout of Teva’s new distribution centre, introducing automation systems throughout the warehouse operation – an Automated Storage and Retrieval System (ASRS) with three cranes and 3,500 single deep storage locations was installed alongside pallet racking complete with 21,000 storage locations, a Pallet Conveyor System, a 78 sort lane Tote Conveyor System and a Pick-by-Light System with 13 pick stations and 910 locations. The whole operation is monitored and managed by SSI Schaefer’s ‘Convey’ Warehouse Control System. Items are picked using three different options; full pallets are selected from the pallet racking, full cartons from the ASRS and single items from the pick-by light system. Ergonomically designed pick stations equipped with hydraulic pallet lifting devices have been installed to help operators. Despatch methods are dependent upon the size of the order and determined by the warehouse management system, which also calculates carton numbers and sizes per order. JP Bednarek, Operations Manager, Teva, said: “SSI Schaefer were able to visualise our needs from the outset focusing on our ultimate goal – to improve upon our customer service levels and product offering. Our new fully automated storage and distribution facility has enabled us to easily reduce our labour overheads by moving from a three-shift operation to two-shifts. Perhaps most importantly, the increased storage capacity allows us to handle immediate needs but will also accommodate future growth in the business.”