SSI Schaefer Magazine - No. 26, Issue 2/2015
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Transcript of SSI Schaefer Magazine - No. 26, Issue 2/2015
Brose Group: Innovative tugger train solution eliminates need for forklifts
Cover story Automotive
4 Vinamilk: Vietnams high-tech dairy distribution centre
No. 26, Issue 2/2015
Logistics service providers
18Khne + Nagel: Innovative combination of systems
2Harrie SwinkelsManaging Director, SSI Schaefer, Giebelstadt, Germany
We are committed to helping our customers maintain their competitive edge in the global marketplace. In-creasing throughput, streamlining material flows and ensuring reliable processes while reducing error rates to almost zero these are just a few of the objectives companies across multiple industries approach us with. To help them achieve their goals, we implement both manual warehousing systems and fully auto- mated, turnkey distribution centres.
Intralogistics has developed into a high-tech industry, with automated warehouse and logistics processes, and purpose-designed software. The technologies we deploy in our projects reflect this trend: they include high-throughput warehouses and storage systems, effi-cient picking solutions, fully automated storage and re-trieval machines, sophisticated robotics, intelligent in-ventory data capture methods, and reliable warehouse management software. Our automotive-themed cover story on the Brose Group spotlights many of these solu-tions in action.
SSI Schaefers warehousing and logistics systems are at the cutting edge of developments we have a tradition of innovation. Against this background, I am pleased to introduce our new product, Navette, in this issue of Update. Our scalable, multi-level shuttle can move up to four totes, trays, or cartons at a time, by means of its two load-handling devices. As a result, it shortens travel time while doubling process efficiency.
The special feature article describes our Customer Service and Support division, which offers new and es-tablished customers a broad portfolio of services. In particular, we address the growing demand for upgrad-ing and retrofitting. Within the scope of these projects, we focus on designing solutions tailored to our custom-ers specific needs helping them create high-availabil-ity storage and maximise their productivity.
Read on to learn more about the exciting world of intra- logistics at SSI Schaefer. We hope you enjoy.
Dafgrd/Nila Sea Foods/ Pistor/Tine/ Italpasta/Vinamilk
14 Food industry
Khne + NagelProject
18 Logistics service providers
Made-to-measure customer service and support
20 Special feature
Growing demand for upgrades
Navette the scalable, multi-level shuttle
Production plant expansion in Asia
22 Inside SSI Schaefer
4 AutomotiveBrose Group: Innovative tugger train solution eliminates need for forklifts
Liebherr-Aerospace/Lely/ Glenbeigh/Belimo Americas/ Klingspor/Schunk
4Innovative tugger train solution eliminates need for forklifts
Brose Group, the worlds fifth largest family-owned automotive sup-plier, called on SSI Schaefers proven expertise when constructing its new logistics centre in the Czech city of Ostrava. The one-stop solutions provider created innovative material flows managed by using a SAP EWM solution tailored precisely to the customers needs to supply the highly dynamic parts to Broses production line.
Cover story Automotive
Each of the four tug-ger train stations has a racking system com-prising four levels and a total of 32 tote chan-nels. A train with four trailers arrives at the station where loading is due to take place.
5Cover story Automotive
Kopivnice, Czech Republic. SSI Schaefer has constructed a new logistics centre at Broses manufacturing site in Kopivnice, near the Czech city of Ostrava. By consolidating storage capacity inside the plant, the Brose Group aimed to cut shipment and external storage costs, streamline material flows, optimise production line supply processes and boost throughput.
To achieve these goals, SSI Schaefer deployed a highly automated logistics solution. First, SSI Schaefer constructed a five-aisle high-bay warehouse with 9,750 pallet positions in a single- deep configuration, with the goal of increasing capacity and streamlining intralogistics. Five Exyz storage and retrieval systems ensure maximum energy efficiency during picking and putaway. A travel speed of 180 metres per minute and lifting speed of 48 metres per minute enable throughput of 200 pallets per hour. The warehouse provides storage for reserve stock, and is connected to an existing building via a bridge. It houses the goods receipt area, the conveyor systems and pro- cessing points, plus an automated small parts warehouse.
Brose opted to pursue the goal of a forklift-free logistics facility. With this in mind, tugger trains are used to supply parts to the production line. All intralogistics processes are fully automated, including loading. The seven-aisle small parts warehouse can store up to 23,520 totes, each weighing up to 15 kilogrammes, in either single- deep or double-deep configurations. Seven stor- age and retrieval systems from the tried-and-trusted Schaefer Miniload Cranes (SMC 1) range enable throughput of up to 840 totes per hour. Totes supplying parts to the production line are loaded at four tugger train stations, located on the upstream sides of the automated small parts warehouse. Once the train has reached the cor-rect position, the totes are released, the locking roller lowers, and the totes roll onto the trailer positions.
Material flow at the logistics centre is also highly innovative. SSI Schaefer has integrated a custom-ised SAP EWM solution into the existing SAP infra-structure. As Jrgen Hergenrther, IT/SAP Project Manager at SSI Schaefer, explains, SAP EWM calculates where the tugger train needs to stop on its journey, and plans the routes and locations of trains, trailers and storage positions accord- ingly. It also organises and controls all underlying processes to ensure loading and supply process-es take place exactly when and where they are needed. The combination of pallet conveying
technology, vertical conveyors and robotic arms that fully automate the depalletising process en-sures high material flow efficiency. Teaching the robotic arms to perform their tasks was a par-ticular challenge and to solve it, SSI Schaefer combined state-of-the-art image recognition with device control technology and SAP EMW.
As Claudia Vogel-Daniel, Project Manager at Brose, says, The new solution has reduced the need for manual input and optimised material flow. Whats more, it has cut personnel costs and enhanced ergonomics. By increasing plant automation, redefining our material flows and deploying an end-to-end SAP solution, we have simplified, streamlined and increased visibil-ity into our processes, and have boosted our throughput, too. We are extremely pleased with this intelligent solution, which has fully automated the supply of parts to the production line.
The Schaefer Miniload Cranes can collect up to two totes, depend-ing on the type of tote. As a result, they en- able throughput of up to 840 totes per hour.
6Mhldorf am Inn, Germany. Since 2001, BMW Vogl has been one of Germanys top 20 BMW dealer-ships. In 2013, a new BMW and Mini centre was opened in Mhldorf am Inn. Within the scope of this project, BMW Vogl contracted SSI Schaefer to implement a new warehouse, comprising fixed lo-cation and wheel and tyre storage systems, with pallet dollies and stackers.
Developing a new wheel storage system was the primary challenge; approximately 1,100 sets of wheels have to be stored on 150 square metres. Capacity and process efficiency were not the only important factors ergonomics is also critical. Our productivity goals shouldnt be achieved at the cost of employees back pain, explains Bernd Rupprecht, responsible for fixed location storage sales at SSI Schaefer. A typical wheel weighs 20 to 25 kilogrammes; SUV wheels tip the scales at 35 kilogrammes. Handling these heavy items is tough physical work, and places great strain on employees backs.
Sets of four wheels are stored double-deep, with each pair occupying one storage position. SSI Schaefer introduced pallet dollies to increase
efficiency. This also improves working conditions, as it eliminates the need for heavy lifting during putaway and picking. The combination of dollies and pallet stackers has proven highly successful. Vertical movements are completed in just 18 sec-onds offering over 50 per cent greater time effi-ciency than conventional systems. Moreover, there are practically no picking errors.
Fixed location warehousing has been a mainstay of the automotive industry for many years. It offers a number of advantages: up to 50 per cent space savings, shorter picking tours due to optimised layouts, and an extremely low picking error rate, as every part has an assigned position. BMW Vogl stores approximately 4,500 spare parts on R 3000 modular shelves on a two-level mezzanine, taking up only 240 square metres of floor space.
Our new storage system enables us to provide our customers with the high-quality service they have come to expect from one of Germanys leading BMW dealerships. It was a pleasure to work with SSI Schaefer; we have formed an excellent part-nership, notes Jrgen Pllner, Managing Director at BMW Vogl.