SSI SCHÄFER News

Holistic Solution in Automation for Handling of Display Pallets in Retail

Fri, 26 Apr 2013 11:17:00 +0200

All for one and one for all – the theme of the novel “The Three Musketeers” gains a new dimension in intra-logistics for the retail industry. The focus here is on pallet handling in handling and distribution centers. With the Schaefer Display Sequencer (SDS), so the labelling of the new, holistic system solution, SSI Schaefer, Giebelstadt, brought to market a new industry specific solution for the automatic handling and warehousing especially for quarter- and Düsseldorfer pallets. With the intelligent combination of established single components from the conveyor technique, steel construction, and IT, SSI Schaefer developed an efficient all-in solution for the automatic, sequenced, and highly dynamic handling of every type of pallet used in the retail industry within one single system. Chief attraction: with this concept the Storage and Retrieval Machine (SRM is already turned into a fully automatic and efficient picker. Besides optimum process safety by automated handling of display pallets without further load supporting material, this brings about a significant reduction of handling cost and an increase in handling performance. In order to increase total revenue and sales, the retail industry puts increased emphasis on half and quarter pallets, the so-called display pallets. Those are especially suitable to replenish the store shelves as one complete unit, present items on sale or initiate impulse buying. Advantages are maximum use of sales areas and shelf space as well as cost reduction by reduced product damage and decreased efforts in storing goods. At goods receiving, the delivery of quarter and half pallets normally happens on Euro pallets as load handling device. At good shipping on the other hand, the display pallets are loaded without load carrying pallets as there are usually no lifting devices for unloading the goods available at the branch stores. This brings about considerable handling efforts as there is so far no adequate solution for efficient handling and picking of display pallets for cross docking. The consequence: high and time-consuming manpower requirements, reduced throughput as well as picking mistakes and restrictions of picking quality. Remedial measure is the so far for the market unique, integrated complex solution called Schaefer Display Sequencer by SSI Schaefer. With it, the intra-logistics specialists from Giebelstadt developed an intelligent warehousing and picking solution from established single components for the automated handling of both pallet types in one system. Advantage for the user: the cross docking of display pallets, the storage, picking, and distribution of half and quarter pallets is done fully automatically and without further load handling devices. This enables fast, cost-efficient picking processes and leads to a minimisation of product damages as well as a reduction of turnover and labour costs. “No other company in the market is currently able to offer such a comprehensive and praxis oriented solution for the cross docking of display pallets“, judges Andreas Oy, head of sales at SSI Schaefer, Giebelstadt. “With the performance characteristics the Schaefer Display Sequencer offers to the user, SSI Schaefer has a unique selling point in the market.” With the SDS all processes from goods receiving to shipping are continuously geared toward an automated handling of display pallets. The delivered load carrying pallets are de-foiled and the stacked half or quarter pallets are automatically separated from the source pallet before the hand-over to the SRM. Specialty: “By the use of a special sensor system, the positioning of the quarter pallets, their feet asymmetrically designed and aligned, on the Euro pallet is at once determined”, Oy explains. “On the basis of this information the display pallets are at the moment of separation from the load carrying pallet and the transfer to the conveying system aligned in such a way that they are lead to the in-feed stations of the central warehouse in continuously equal positioning.” This increases safety and stability during the following intra-company transport and further automated handling. The used conveyor system is a modified development of established conveyor components by SSI Schaefer. The design is tailored to the transport of pallet types used in retail. The same is true for the new V-load handling devices (LHD) of the SRMs that store and retrieve the pallets in the rack storage system. Controlled by the material flow system and with the information of the superposed warehouse management system the SRMs identify at the point of reception of the pallets the type of the respective pallet. Depending on the supply, the LHD takes either one half or two quarter display pallets in one operating sequence. By means of the even positioning of the quarter pallets at the pick-up station the whole handling of the quarter pallets on the conveying line as well as by the SRMs happens in the predetermined positioning. This increases the dependability of the processes, provides failure-free sequences, and increases the throughput. Moreover, the LHD of the SRMs as well as the storage positions in the rack storage are tailored to this standardised alignment. “Nonetheless, the compartments in the rack storage can flexibly be used depending on available space with three half or up to six display pallets”, Oy explains. For this purpose, a rack system with special support beams was developed for the new V-load handling device on the basis of available components. They are conceptualised for use in all SSI Schaefer standard racks. Thus, they can be installed in rack-supported as well as in-house constructions. The specialty of the new system design that SSI Schaefer developed for the automated handling of all current pallet types as a mix shows most notably at the stock release processes: With the SDS the SRM conducts downright picking runs during the retrieval process. At one play, e.g., the V-load handling device retrieves two quarter or one half pallet from the storage position and transfers them to the goods-out conveyor. Specialty: the retrieval of the different types of pallets can happen from various storage positions. “Thus, with the retrieval from the rack storage, the SRMs are already taking over a sequencing and order picking according to the requirements of the branch stores”, Oy explains. “This makes the Schaefer Display Sequencer design an optimum system solution for the handling and distribution of the retail industry that more and more tailors the distribution structures to the quarter and half pallets.” Retrieval and transfer of half and quarter pallets to the shipping conveyors as well as the allocation at goods-out are also being conducted according to store requirements and without slave pallet. Another outstanding feature of the system solution is: it is level with the ground. “Thus, display pallets can comfortably be accessed and shipped with various transport vehicles”, Oy explains. “Forklift trucks with extra-long forks that are designed for picking up several pallets can take up to four half or eight quarter pallets in one step with these pallets already arranged in the right order as requested by the store.” For newly built plants a deepening of the floor slap is designed for these special goods-out lines. At goods receiving/goods shipping, the SDS concept allows for the sorting and handling of several hundred quarter pallets per hour depending on the plant layout. “With this turnover rate we are in a high frequency area with our Schaefer Display Sequencer”, Oy judges. Furthermore, for the material flow controls, interfaces for all current warehouse management systems such as WAMAS by SSI Schaefer or SAP based solutions are available already in standard designs. “With the automated pallet handling of half and quarter display pallets – and, of course, also Euro pallets upon demand – in one system as well as the designed sequenced picking already in rack storage the Schaefer Display Sequencer offers distinctly improved turnover performances to users, a significant reduction of failure and damage quotas during the handling of display pallets and a sustainable increase of service levels”, Oy sums up. “Thus, the SDS is an integrated, holistic solution in the industry for the current practice requirements in retail as well as for an increase of competitive capacity of producers and service providers.”

SSI Schaefer to Showcase Harrods Installation at IMHX

Tue, 05 Mar 2013 17:18:00 +0100

Visitors wanting to get a detailed behind the scenes look at Harrods new Thames Valley Distribution Centre in Thatcham, Berkshire, should take a seat in the IMHX Case Study theatre on Wednesday 20 March at 3pm. The case study session, presented by SSI Schaefer, will cover the complete fit-out of Harrods new site focusing on project objectives, challenges, automated and bespoke storage solutions including details on the latest extended warehouse management software, SAP- EWM. Following a seamless transition from its former site in Osterley, West London, the 346,000 sq ft facility fitted out by SSI Schaefer is now fully operational and the sole UK distribution centre for the Knightsbridge store and other outlets. Together with the team from Harrods, SSI Schaefer ensured the facility was fully operational without impacting on service within a 15 month time frame. Simon Finch, Deputy Director, Distribution, Harrods, said: “From the outset of this project we were looking for a turnkey supplier that could project manage the entire fit-out of the warehouse, and we found this in SSI Schaefer. Their expertise in systems integration, design, installation, delivery and on-going service and maintenance support proved to be a winning formula for such a relocation project of this size.” The whole site is fitted out with the very latest materials handling equipment enabling the faster movement of goods with increased replenishment accuracy and frequency as well as much greater storage capacity - holding over 10,000 product lines, many more SKUs are cross-docked and delivered into London continually throughout each and every day. To kick things off SSI Schaefer immediately installed narrow aisle pallet racking that provided instant additional storage capacity but also ticked the box to accommodate future sales and growth of the business as and when required. A fully integrated and automated storage, handling and picking system was then designed, supplied and installed. The innovative system comprises a four aisle miniload crane system servicing 43,000 tote storage locations, transport, replenishment and picking conveyors with an automatic labeling system, automated goods to man workstations with pick-to-tote- technology, forklift control system, medium item shelving, man up order picking in very narrow aisle (VNA) pallet racking to 12 metres, unique big ticket high bay racking integrated with special large product order picker machines, process area workstations for inbound stock handling and outbound store preparation, 10,000 store delivery totes and handling equipment. SSI Schaefer also has sole responsibility for the centre’s entire Warehouse Management System which is fitted out with SAP’s latest software, EWM – Extended Warehouse Management – this crucial role for the smooth running of the site was given to SSI Schaefer due to their in-house expertise and ability to configure and deploy EWM. The system provides Harrods with real-time information and a high level of process and inventories transparency enabling precise planning of warehouse steps as well as efficient distribution and storage processes, managing both the manual and automated processes. The centre, which has achieved an excellent rating from BREEAM highlighting the centre’s excellent energy performance and recycling facilities, was opened by Michael Ward, Managing Director of Harrods and the leader of Thatcham Council, Cllr John Boyd with Jaap Vos, Director of SSI Schaefer UK in attendance. The project represents a major investment for Harrods and a long term commitment to SSI Schaefer who will provide on-site resident maintenance.

SSI Schaefer to showcase championship racing car at IMHX

Mon, 25 Feb 2013 11:07:00 +0100

As the official partner of Volkswagen Motorsport in the 2012 Volkswagen Scirocco R-Cup, SSI Schaefer will present the yellow branded Scirocco at IMHX that raced at Brands Hatch alongside former Formula One World Champion, Damon Hill. The UK leg of the tournament, the third race out of eight, saw Jonas Giesler, driving the yellow Schaefer branded Scirocco, take second place behind more experienced driver Ola Nilsson. After a nail-biting 25 laps Nilsson relegated the young German driver Giesler, who had started from pole, and his fellow countryman Jann-Hendrik Ubben, to the other podium places. One of the race victims was Legends entrant Damon Hill who, after an incident of body contact, was forced to retire from the race with a technical defect after only seven laps. The 1996 Formula One World Champion, Damon Hill, who ended his motorsport career almost 13 years ago, made a one-off comeback in the Volkswagen Scirocco R-Cup for the benefit of his children’s charity ‘The Halow Project’ for which Volkswagen Motorsport Director Jost Capito presented a cheque to the value of 10,000 euros. The car will be on display throughout the four-day IMHX show situated outside the main entrance to Hall 18.

Picture Perfect from SSI Schaefer at IMHX

Wed, 30 Jan 2013 11:15:00 +0100

Visitors to IMHX can expect the complete works from SSI Schaefer. The red carpet is literally being rolled out to welcome all guests to the impressive 380 sq metre stand that will not only feature two brand new products to the UK market but will also capture Schaefer’s complete product range and capabilities. Two exciting and innovative products new to the UK market, the LogiMat and the Schaefer Auto Cruiser (SAC) from SSI Schaefer, are certain to attract some attention. The LogiMat, standing at six metres high, is a goods-to-man picking, space-saving, vertical lift storage system ideal for small parts storage. It offers high order picking accuracy and will be part of an interactive live demonstration of parts picking, transport and assembly. The SAC is a remarkable and innovative system specifically designed to bridge the gap between forklift transport and traditional conveyor technology – it’s an extremely competitive and flexible transport system for low to average throughput. SSI Schaefer will also be showcasing its brand new QX plastic container series - a container solution providing excellent compatibility with automated and robotic handling systems. With a standard footprint of 600 x 500mm, the QX works well within the UK Pallet pool offering greater internal storage capacity for larger components. As one of the largest producers of plastic containers SSI Schaefer has always been at the forefront of container handling systems which is why visitors will get to view a scaled demo unit of an ‘up-to-the-minute’ roller and belt conveying system using the very latest conveyor technology combining picking with container and carton transport. A full size powered mobile racking working demonstration using the most recent market safety and control technology will be on display. Providing a cost effective solution for high density storage of palletised goods, mobile racking systems can be configured to handle both standard industrial and Euro pallet sizes. Schaefer’s Orbiter is once again making an appearance – a deep pallet, high density storage and retrieval system leading the way providing safe and controllable technology. State of the art lifting mechanics and Operative Protection Docking Station, complete with unique Power Cap technology allows the Orbiter to be recharged each time it enters the docking station ensuring optimum efficiency gains. IT specialists will be on hand to offer expert advice and to demonstrate WAMAS, the very latest technology in warehouse management and warehouse control systems including SAP integration for both manual and automated operations. The latest design in unique bolt and clip free adjustable R3000 shelving will be on the stand giving visitors a close up viewing of how the system can be configured to support multiple floor levels without the need for additional costly steelwork. A ‘project wall’ will feature examples of automated high bay pallet storage illustrating the advantages and benefits associated with the automated storage and retrieval of palletised products as well as combined picking and storage systems across a wide range of industries. Finally, an ergonomic industrial assembly workstation fully integrated with small parts storage, picking and transport system will be on display designed to increase efficiency in a host of different production environments.

75 Years SSI SCHAEFER

Thu, 13 Dec 2012 13:43:00 +0100

Neunkirchen, Germany. In seven and a half decades, SSI Schaefer has undergone rapid development, creating a successful company history in the process: From the one-man business operating from a cellar workshop, to a large company group with around 8,500 employees and multiple international subsidiaries. Today, SSI Schaefer is the world’s leading provider of warehouse and logistics systems. In 1937, Fritz Schäfer, a trained plumber and welder, founded his company to produce “factory-made sheet metal goods”. Initially, he began with the production of transport containers and other sheet metal items. In 1953, the established family company launched the groundbreaking development of the Lager-Fix container onto the market. Since then, the range of boxes and containers at Schaefer has grown continually. Matching shelves for the containers were soon added to the product range. In the 1970s, other storage systems were developed, such as the high bay racking system. The same decade saw the formation of the waste technology division and the office furniture division followed in the 1980s. Internationalisation took a step forward and additional foreign subsidiaries were gradually founded. The turn of the century saw the formation of the SSI Schaefer Group, covering the entire product range of in-plant logistics with its varied associated companies. The initial foundation of the group was the integration of SSI Schaefer Noell GmbH, formerly part of the Preussag-Noell Group, in 2000. As a general contractor for complex logistics solutions SSI Schefer Noell, Giebelstadt, has been supplying its highly innovative, automated logistics solutions to complement the warehouse equipment from Fritz Schaefer GmbH ever since. One year later, SSI Schaefer Peem GmbH, Graz, was added to the group. With modular order picking and conveyor technology, SSI Schaefer Peem completes the product range of the group. In 2008, the SSI Schaefer Group was strengthened further with the addition of Salomon Automation GmbH in Friesach near Graz, Austria, which offer outstanding software and logistics expertise. The WAMAS warehouse management software provides extensive application options for tailored customer solutions. With this comprehensive range of products and services, SSI Schaefer operates in the market as a total solutions provider for in-plant logistics. This is something that our customers value very highly. This is because they receive a complete solution from one source – with the assurance that the various components, thanks to their standardised interfaces, can be seamlessly combined to work together. You’ll find more interesting fact about SSI Schaefer’s history in our anniversary brochure.

Destination IMHX, Destination Schaefer

Wed, 28 Nov 2012 11:20:00 +0100

Visitors after the X factor at IMHX should look no further than SSI Schaefer for inspiration. Offering an eye-catching stand that will draw the crowds in, SSI Schaefer will be looking after its guests within the impressive hospitality lounge and bar area dedicated to all stand visitors – providing both the ideal networking spot and opportunity to get to know the faces ‘behind the scenes’ that contribute to Schaefer’s leading reputation within the UK materials handling industry. Not only will the stand be packed full of innovative solutions designed to meet and exceed the storage, order picking and handling demands of today’s competitive logistics industry, SSI Schaefer’s experienced sales and design teams will be on hand to discuss existing and future business challenges. Providing total integrated support to each and every one of its customers, SSI Schaefer’s team of top industry specialists use their skills and knowledge of combined standard storage and automation products to offer the widest range of possible solutions to any sector in the market, from Retail to Defence, Pharmaceutical to Education and Automotive to Food. Jaap Vos, Director, SSI Schaefer UK, says: “Whilst there are many organisations that actively work in this area only a few actually manufacture the diverse range of products and systems needed to satisfy the demands of this expanding industry. “SSI Schaefer has the ability to provide every aspect of project management, from planning and design, through to consultation and implementation. IMHX is the ideal platform for existing and new customers to view firsthand the array of product and system solutions available to them backed up by a team of industry specialists.” Traditional solution routes will stand alongside cutting edge automated systems, both offering rapid returns on investment, all manufactured within the SSI Schaefer Group.

Innovative material flow concept for modular shelving system

Tue, 20 Nov 2012 13:11:00 +0100

In line with its principle of 'premium service for premium sports cars', over the past few years Porsche has redesigned its spare parts supply logistics for customers and consolidated logistics functions for development departments at a single site. The company's new central spare parts warehouse at Sachsenheim was constructed in two phases between 2007 and 2010. A network of outlying warehouses which were increasingly hampering the efficient flow of material were closed down and the storage space and processes transferred to the 112 900 m² facility at Sachsenheim. This was the first point at which Porsche drew on the expertise of SSI Schaefer, which supplied the shelving systems for large and medium-sized parts. This project having been completed successfully, it was only logical to choose the Neunkirchen-based company to fit out the new distribution centre.So in February 2011 SSI Schaefer was awarded the contract to fit out part of the warehouse, destined to supply parts to Porsche's development engineers. Every day 350 parts are transferred into the 10 000 m² storage facility and around 2000 components are shipped out. The warehouse stores small parts, medium parts in containers of up to 1200 x 800 mm (MT1), medium parts in containers of up to 1400 x 1700 mm (MT2), and bulky large parts (GT).Between February and August 2011, SSI Schaefer set up three static pallet warehouses for medium and large parts. For MT1 parts there is a 12-aisle pallet store, with 10 aisles of eight levels and two aisles of seven levels. The MT1 narrow-aisle warehouse contains 5740 pallet storage spaces. Another 1438 spaces are available in the five storage levels of the 7-aisle MT2 warehouse. To store large parts there is a single-aisle pallet warehouse with 140 pallet spaces over five levels. "Thanks to the flexibility of our R 3000 shelving system, the layout of the new warehouse posed no problem," says Arne Limper, Sales Group Manager for shelving installations at SSI Schäfer. "The key thing for the Porsche solution was to gear the storage areas towards a consistently efficient material flow, from the receipt of goods to picking and then loading the materials in outgoing goods."This placed particular demands on the processes in the small parts warehouse, which had to offer an intelligent solution. Sascha Drechsler, a planner at Porsche, sums up the criteria that the installation had to meet: "Compact but process-optimised, a low degree of automation to ensure flexibility, designed to cope with peak load but with the potential to handle future increased throughput." The company therefore opted for a two-storey modular shelving system on a floating platform. The advantage of this configuration is that it uses the full height of the building while leaving the space underneath free for the processing of incoming and outgoing goods. The two platforms, measuring 2000 m² each and at 5 m and 7.5 m high respectively, provide close to 9000 metres of shelf space for small parts containers weighing up to 15 kg. In total there are 42 000 containers in circulation. The challenge was to ensure the rapid and smooth movement of goods to and from the platforms. Both levels are equipped with transfer points for forklift-assisted goods movements, but these are simply an added extra for exceptional scenarios."For standard inward and outward transfer processes we had the option of using either a ramp system for trucks and lifting gear or a conveyor system and conventional lift systems," explains Drechsler. "But neither was able to satisfy our material flow concept or growth strategy." A ramp would have taken up floor space, so was quickly eliminated from consideration; and conventional lifts proved to be a bottleneck for the planned processes. "The small parts warehouse needs to cope with peak periods and allow for future increases in throughput," says Drechsler. "This means fluctuations of at least +/- 20% Two conventional lifts would have been incapable of handling this. And three would have made the system too big." Jürgen Kalkenbrenner, Sales Manager for automated complete systems at SSI Schaefer, explains another problem: "Conventional lifts are associated with unnecessary delays and tie up a lot of manpower. Everyone's familiar with the situation: you're waiting for the lift and when it finally arrives it's full. For logistics processes, this just won't do." During the implementation phase, the intralogistics specialists at SSI Schaefer and the planning team at Porsche Logistik developed a new and innovative conveyor solution which would soon become the "core of our small parts storage and picking processes", as Drechsler puts it. The SSI Schaefer approach was to install a flexible automation solution for transferring goods to and from a conventional lift system. "This is the first step in automating a multi-storey modular shelving system," says Kalkenbrenner.Inward and outward processes are kept completely separate and generally follow the person-to-goods principle. Incoming goods are processed in the 2000 m² area underneath the platforms. Items for the small parts warehouse are repacked in containers and stacked on picking carts. A lift serves both platform levels and can be used for inward and outward transfer at the same time. Unlike basic lifts, the process is completely automatic. Warehouse personnel move the carts to a transfer station and press the button for the desired platform level. The process is then completed automatically without any further manual input.On each side of the lift is an electric conveyor belt – one for loading carts and the other for discharging them. The belt conveyors also serve as a buffer for the next cart load. When the button is pressed the conveyor transports the loaded cart into the lift system. Quick-close doors seal the lift area and the two-column lift carries the cart to the selected level. At the transfer station the rolling gates open and the cart is ejected on the discharge side. "There is no need for anyone to be present to take the cart out of the lift," says Kalkenbrenner. "In addition, the levels are continually supplied with inward goods containers." At the same time, any carts on the other conveyor belt can be automatically transferred to the column lift with outgoing containers and carried to another level. "This saves precious time," adds Kalkenbrenner.A rotating table is installed at ground level to eject the roller containers. This table turns the carts and outgoing picking containers by 90 degrees before discharging them on to the outgoing conveyor. This ensures that the roller containers are correctly oriented below the platform structure so they can be consolidated in the outgoing goods area.Efficiency calculations performed by Porsche Logistik show that the new system configuration is paying for itself after just a short time in operation thanks to the elimination of waiting times. "But this is really just an extra benefit," says Drechsler. "The efficiency of the material flow was our top priority. The smart combination of conventional technology and additional automation components has produced a convincing system concept. It's a process-optimised concept with which we can achieve guaranteed throughput and respond to potential growth."

Turn-key Logistics Centre for Automobile Supplier

Thu, 15 Nov 2012 10:03:00 +0100

Brose, the internationally operating supplier for the automotive industry, entrusted the intra-logistics specialist SSI Schaefer, Giebelstadt, with the design, planning, and turn-key building of a modern logistics complex for their manufacturing plant in Koprivnice, Czech Republic.As Partner of the international automotive industry, Brose supplies around 80 automotive brands and more than 30 subcontractors with mechatronic systems and electric motors. About 21.000 employees are working at 53 locations in 23 countries. The new logistics concept at the location Koprivnice allows for highly automated in-house solutions in logistics.Within the scope of supply and services of the systems supplier SSI Schaefer are one automated high-bay warehouse (HBW) and one automatic miniload storage system that form the backbone of material supply in production. With about 9.700 storage positions, the rack-supported HBW offers space for storing Euro pallets and lattice boxes. With single-deep telescope load handling devices five one-mast storage and retrieval machines (SRM) of the type “Exyz” take care of energy efficient storage and retrieval. The miniload has about 23.500 tote storage positions and provides for single- and multiple-deep storage by way of seven SRMs with carton gripping load handling devices from the family of established Schaefer Miniload Cranes (SMC).The new concept allots slugs to transport material to production. Extensive pallet and tote conveyor systems, automatic depalletizing, repacking stations, as well as a loading station for the slugs directly linked to the miniload complete the innovative design. As far as warehouse management and controls are concerned, SSI Schaefer provides for an extended material flow system of the entire facility as well as an interface-free connection to the SAP system with the SAP EWM module.With the automation, Brose not only achieves a significant increase of supply guarantee and a reduction of logistic costs. With the realized solution, the automotive supplier further profits by more robust and transparent supply processes. With this project SSI Schaefer once again emphasizes their leading role in complex system solutions for the automotive industry.

Biggest pasta producer in Hungary opts for warehouse extension

Wed, 24 Oct 2012 14:40:00 +0200

How it all began The company history dates back to 1971, when due to an emergency situation 12 farmer families were forced to team up and established the pasta factory GYERMELYI. It was their common sense and sound understanding, which allowed them to quickly pick up the basics and secrets of pasta production. Due to the strong family ties, their diligence and economy, the factory soon became the biggest pasta producer in Hungary. Every day, tons of pasta are produced and delivered to 100 customers all over Eastern Europe. The first fully automated warehouse in GYERMELYIIn 2004 general contractor Salomon Automation developed a fully automated high bay warehouse equipped with more than 6.200 pallet locations. Three aisle-bound stacker cranes managed the transport of the pasta to the designated locations. Already back then, the supersized warehouse was planned in such a way that it would meet the requirements of the future, assuming that by 2006 all capacities would be fully utilised.The extensionHowever, due to the remarkable growth and the storage of new goods categories, GYERMELYI was soon pushed to its capacity limits. Consequently, Salomon Automation was put in charge of the extension of the fully automated warehouse. Within only 13 months of construction time, the high bay warehouse was equipped with 2 additional stacker cranes and the 6.200 storage locations were extended to just under 9.400 locations. The now fully automated warehouse management is carried out by means of 5 stacker cranes with load handlings for double-deep storage. The automated pallet conveying system was extended by 2 additional cross transfer carriages as well as 8 new dispatch ramps. Due to the enormous space requirements, the picking was transferred into an adjacent hall. In order to integrate both warehouse areas in the fully automated process, a connection conveying system was installed not only in the goods-in, but also in the goods-out area. With a total of 20 roller tracks, the goods-out now ensures an organised outbound delivery process. The softwareIn the meantime, the warehouse management system WAMAS controls and manages the entire logistics processes. In this way, WAMAS assumes the operational control and management of goods flows of logistics and support processes including resource planning and work progress. Every day, up to 340 pallets at the goods-in and up to 350 pallets at the goods-out are handled. Additionally, more than 500 articles are managed in the warehouse, which ensures a timely outbound delivery or product ranges to all stores.Profitability, quality, ergonomics & sustainabilityThe realisation of the new distribution centre generated a number of outstanding advantages, which include process and personnel cost savings due to the continuous logistics software, a higher energy efficiency as well as ergonomic work stations.Salomon Automation's goals for the customer include: Performance optimisationQuality improvementWork simplification In case of GYERMELYI we managed to realize all these points to the utmost customer satisfaction.

Efficient Material Flow in Pharmaceuticals Distribution

Thu, 20 Sep 2012 13:33:00 +0200

Every company wants to save costs, respond flexibly to changes in the marketplace, and remain competitive. This only works with perfectly orchestrated internal processes, however. This was Pharmapool's experience, too. Optimise logistics structures, design processes more efficiently, and utilise cost savings – the requirements were defined when the pharmaceutical company began planning a new, central distribution centre in Widnau at the beginning of last year. Regardless of individual interests of the pharmaceutical sector or branded products, the wholesaler for doctors founded in 1996 offers its customers in Switzerland a wide range of medications, incl. generic medicines, consumables, doctor's practice and lab equipment, as well as items on the Drugs and Medical Equipment List (Mittel- und Gegenstände-Liste). In the process, Pharmapool supplies doctors, chemists and consumers reliably within 24 hours with boxes of medicines carefully packed by hand in individual shipments. "The old warehouse structure couldn't keep pace with the requirements of modern order processing and distribution logistics", explains Mr. Binkert, Managing Director of Pharmapool AG, Widnau. This is because all work in the warehouse was previously carried out manually using picking lists. This takes time and costs money. "This is why we have decided to set up a new hall with modern warehouse technology as well as a new picking strategy to exploit all the potential in terms of internal processes", states Mr. Binkert. The key points for Pharmapool were to optimise and increase performance and quality in the picking process. The intention was to base the solution on a carefully orchestrated, custom combination of modular systems.The scope of services provided by SSI Schaefer ranged from system planning and consulting to implementation, through to after-sales service. Together they started work on implementing the project in line with all the requirements and on schedule. To achieve this, SSI Schaefer worked closely with architects and the Pharmapool project team, right from the start. This meant that proposals from SSI Schaefer on the hall layout were incorporated at an early stage to facilitate the optimum design, meeting all requirements, for the subsequent installation of the picking system. An intelligent material flow concept with as much automation as necessary, and as little automation as possible; this was the guiding principle followed by SSI Schaefer in developing the project. "We examined all the requirements and the available options in great detail to achieve the optimum result for Pharmapool. Along the way, this project demonstrated very clearly that a semi-automated system incorporating carefully orchestrated components can produce the perfect result in the pharmaceutical sector as well", reflected Bruno Skraber, Head of Department at SSI Schaefer, Switzerland. A carefully designed, semi-automated total system concept comprising conveyor technology, paperless "Man to Goods" picking (RF Picking) combined with ergonomic picking stations and appropriate warehouse technology has been ensuring exceptionally efficient processes since the end of 2011. The new system on a 1300 square metre base area is equipped with an R3000 modular shelving system providing 12,000 storage spaces. A conveyor technology system over 80 m long with eight picking zones was installed in the middle of the modular shelving system. Here, the conveyor path ensures rapid transport of the order containers between the picking stations and the dispatch area. Within the zones, SSI's WAMAS C software guarantees fast and transparent picking processes. The conveyor technology provides the foundation for the rapid implementation of the new distribution centre, forming the centrepiece of the system. This carefully designed concept in Widnau now prepares around 10,000 different items in 200,000 packages ready for retrieval. They are stored in 9000 Euro-Fix containers from SSI Schaefer. The individual zones are interconnected via the automatic conveyor technology, forming a complete unit. "This structured, transparent system design means that this Pharmapool warehouse offers a high level of efficiency", explains Skraber. All jobs are recorded directly on Pharmapool's in-house ERP system. This then communicates directly with the WAMAS C logistics software that initiates the retrieval operations. And off we go. WAMAS tells the system, and automatically the workers, how many containers should be required for a job. The workers send the empty containers via conveyor technology into the warehouse or to the picking zones. "The use of containers and conveyor technology permits the automation of transport processes in combination with a manual system, ensuring an exceptionally fast material flow", explains Skraber. Even before the transport containers follow their routes to one of the eight picking stations, they are automatically scanned via light barrier and a staff member attaches a printed order docket. This is recorded on the system and paired up with the container. The transport container then makes its way to the relevant picking zone. Once there, it is scanned by a picker with a small finger scanner connected directly to the hand-held terminal. This tells the worker digitally and with no delay where the right items are to be retrieved. Controlled via the system, the picker is led to the correct storage location. At the storage location, there is another label with a barcode scanned by the worker before s/he removes the goods. To ensure that no errors occur, the barcode for the goods is recorded and acknowledged. This increases the order picking quality. After completing each picking process, the worker in the relevant zone sends the container back into the goods flow. Once the order has been compiled in full, the goods are automatically sent in the direction of the despatch area to the last workstation. Here, the order is checked once again, packed and released for dispatch. 15 dispatch shipments leave the warehouse each day. The new system has achieved an increase in picking efficiency of around 30%. "Following a brief startup phase and familiarisation with the new way of working, the system has accelerated the material flow considerably. And the clear organisation of the picking zones and new picking strategies have streamlined order processing and compilation. The error quota has also dropped to virtually zero", according to Mr. Binkert from Pharmapool. It is not just the warehouse that is more efficient; employee work quality has also increased considerably. This is because the conveyor technology takes the strain off picking staff and instead supports the workers in compiling jobs easily and without errors. The bright and friendly atmosphere in the warehouse also provides a more relaxed working environment."There are no interface problems at all, either in project implementation or in the system design", continues Skraber. The implementation process was carried out with purpose and flexibility via teamwork. "We are very happy with the project management from SSI Schaefer and the results provided by the solution. Our expectations have been more than met with the project and we are now absolutely ideally equipped for the future", summarises Mr. Binkert from Pharmapool.

Combined systems for optimum material flow in a hospital

Mon, 20 Aug 2012 11:21:00 +0200

The healthcare sector is undergoing rapid change. As hospitals face rising cost pressures, the pressure of competition and the continuing necessity of new investments, it is essential to optimise internal processes. If these processes are not carefully coordinated, the hospital is likely to experience supply difficulties. The logistics inside a hospital are more complicated than you might think. To satisfy both current and future requirements, hospitals are now being forced to identify untapped rationalisation potential, develop new organisational structures and optimise processes.Bern University Hospital, founded in 1354, is playing a leading role in this process of change. The hospital occupies an important position in the Swiss healthcare sector. With a staff of over 7100, the hospital provides high-quality medical treatment and individual care to 52 000 inpatients and more than 263 000 outpatients every year. This makes for complex intralogistics.The hospital already had a central warehouse designed by SSI Schaefer where medical consumables and other materials are order-picked. To supply all wards, including some non-bed wards, a modular cabinet solution was gradually introduced. This system offers significant quality benefits when it comes to material management. However, from a logistical point of view it also means more picking positions to be processed. The modular cabinet system is based on the kanban principle. Items are stored in defined compartments. There are two identical compartments for each item, each containing the quantity expected to be used up before new supplies are ordered. When one compartment is empty the replenishing process is initiated. Until new supplies arrive, goods are removed from the second compartment. This system ensures fixed order quantities and optimum reliability of supply. A project group was organised to evaluate a more efficient picking solution. The objectives were to take the burden off the central warehouse, improve efficiency, reduce personnel requirements, increase supply quality, minimise errors and simplify processes. "To achieve these goals we were prepared to adopt a new approach. So we opted for a second, decentralised, inventory-managed warehouse and a move towards automation," says Thomas Nietlispach, the manager of the central warehouse."Time always brings change. This is why we offered the customer a modular solution that is not only perfect for the present, but also incorporates a flexible design that can be expanded as a modular system as required", explains Bruno Skraber, departmental manager at SSI Schaefer Switzerland. The automation technology was chosen to suit the customer's own process and therefore be as cost-effective as possible, and now satisfies all the hospital's requirements. "This system, a combination of storage and conveying technology, proved to be ideal, and the customised combination of modular systems achieves the stated aim of increasing supply reliability while taking the burden off personnel," says Skraber.The new facility was installed without any interruption to normal warehouse operations. The task was not without its challenges: "The new warehouse was to be installed in an existing space. So the project had to be implemented within a defined area of 500 m²," Skraber explains. Particular attention was also paid to ergonomics, as one of the objectives was to reduce personnel workloads. The new warehouse now holds around 1000 different items. For optimum storage, there is live storage racking for around 100 'A' products (fast movers) and modular racking for 'B' and 'C' products (medium and slow movers). For bulky items such as nappies and surgical materials there is a dedicated pallet picking zone. All storage spaces are managed by WAMAS C, the SSI Schaefer logistics software. The warehouse management system is linked in to the customer's SAP system. "WAMAS C makes process control absolutely transparent. All processes are clearly structured," says Skraber. Orders are picked using handheld RF terminals in three zones, which are directly interlinked by the container conveyor. The live storage racking with fast-moving items is positioned right next to the conveyor. This allows goods in this zone to be picked efficiently at an ergonomic height and placed directly into the containers on the conveyor belt. The modular racking containing B and C items is located directly behind the warehouse staff, so they can also be picked in just a few steps. The facility is manned by three to four people working a single shift. "The new solution not only makes our processes more transparent, it also reduces picking time by over 50% without any reduction in quality. This gives staff more time for other logistics tasks," says Nietlispach. As for the flow of goods and information, the requirements of each ward are entered into an MDE device each day and sent to the SAP system. Orders are sorted and picked according to internal priorities and delivery routes. The delivery slip is then printed in the picking warehouse before the warehouse team scans the order and links it with up to five containers per order. En route to the warehouse, the software automatically registers in which of the two zones the containers will be discharged and when. Once the order container has been transported into the picking zone by the conveyor belt, an employee scans the barcode on the container and the picking instructions are displayed on the handheld terminal. Every pick is confirmed with a handheld scanner for checking purposes. "This increases the order picking quality," says Skraber. "The customer always receives a correct, error-free delivery." Once the order is complete, the conveyor automatically transports the picked items to the outgoing goods area. Here, the containers are placed on caddies and supply assistants deliver them to the modular cabinets for each ward. In the event of problems, SSI Schaefer's IT team can perform remote error diagnosis and troubleshooting.Transparent, efficient and economical processes in a user-friendly solution tailored to the hospital's requirements. And with an error rate of almost zero. "We're very pleased that we chose to make the leap into automated technology," concludes Nietlispach.

Steel construction becomes more European

Fri, 20 Jul 2012 08:42:00 +0200

Whether it’s an EN, DIN or ISO – a steel construction company has to follow a lot of technical and legal specifications. In the course of harmonizing these rules throughout Europe, the CEN (Comité Européen de Normalisation), the European Standards Organization developed the so-called Eurocodes. Eurocodes standardise the rules on structural design in construction – Europe wide. The goal is to remove technical obstacles for industry and trade within the EU and promote the free rendering of services. Eurocode 3 is active since July 1st, 2012 and replaces the previously central series of standards DIN 18800.SSI Schaefer prepared for this change well in advance. From July 1st onwards, we will provide stability checks only according to Eurocode 3. This guarantees that customers receive the requested quality, state of the art, and secured quality.At the same deadline, all the connecting parts responsible for stabilizing the steel construction (for instance a racking system) need to have a CE label or a sign of compliance with national construction regulations. In case it is not possible to use connecting parts with a CE label, the approval has to be requested on an individual basis, which means for this project only or as a general approval under building law. For example, SSI Schaefer is the only producer of racking systems, who has a general approval for using galvanized 8.8 connecting parts: consistently high quality and quick delivery are only two of the resulting advantages that customers can expect from us.

WAMAS Warehouse Management Software for Automated Logistics Centre

Mon, 16 Jul 2012 07:36:00 +0200

Most certainly you know how it feels to be looking forward to getting yourself that special gadget that you have been longing for for quite some time already? A hightech TV-set or the PlayStation of the latest generation? And surely you are also familiar with the kind of disappointment that comes over you when the sales person reveals: “We are very sorry, but there seems to be a shortness of supplies”. Or: “We must apologize; according to our warehouse stock, we should have one piece available but we cannot seem to locate it right now”. Yes? What you might not know, however, is that many of these problems are due to deficient processes in logistic procedures.This was one of the reasons for Big Bang, d.o.o. the Slovenian market leader in the sector of audio, video and computer products to opt for the warehouse management software WAMAS by Salomon Automation. In cooperation with Salomon Automation Big Bang started in spring 2012 the modernisation process of the logistics centre in Celje, which supplies 19 own stores and other wholesale customers all over Slovenia with goods. The facts As a subsidiary of the Merkur Group, Big Bang d.o.o. is the Slovenian market leader in the sector of audio, video and computer products and domestic appliances. A total of 450 employees in 19 stores, distribution, wholesale and internet stores attend to the needs of both final customers and companies. Within its ample assortment Big Bang d.o.o. offers a variety of products and a wide range of quality. Over 4.000 articles are stored in about 4.500 pallet locations on a 6.600 m² site. More than 20 employees are in charge of operating the warehouse and they distribute about 8000 items? or 41.000 pieces per month to the customers. The solution The warehouse management system WAMAS 4.9 controls all processes from goods-in to picking and goods-out. The system is fully interconnected with the enterprise resource planning system of Big Bang so that all the relevant processes may be dealt with automatically across all systems.The paperless handling of business processes, the ease of use of the system and the clear, physical representation of the warehouse in the system were all factors that convinced Big Bang of WAMAS. Ultimately Big Bang chose WAMAS because by improving the structuring of processes the storage capacity utilisation of 50% up until now, can be increased remarkably. Furthermore an increase in picking as well as a lowering of the error rate is to be expected due to the implementation of a process-oriented control in picking.So the goals of Big Bang are easily explained: Cut logistics costs Reduce errors to a minimum Increase availability of goods in the storesIncrease transparency and efficiency in the supply chain WAMAS® – the Warehouse Management System WAMAS - the warehouse management system by Salomon Automation controls, monitors and optimises the full range of logistical processes. Hereby Pick-by-Voice, Pick-by-Light and radio picking are fully integrated. The logistics software allows both standardisation and differentiation within one system and covers the logistical processes from goods-in to internal transport, from picking to packing and shipping of the goods.Among the circle of customers who use WAMAS there are numerous enterprises such as for example Migros, XXXLutz, SPAR, EDEKA, Gebrüder Weiss, Kraft Foods, Festo, Desigual, Fresenius Kabi, Head Sport, Rauch Fruchtsäfte and many more. They all benefit from optimised processes resulting in an increase of quality and a simultaneous cost reduction.

Nottinghamshire Police Benefit from New Trackless Mobile Shelving

Mon, 11 Jun 2012 07:20:00 +0200

The system, which now houses over 7500 euro sized plastic containers for material storage, was chosen and installed into an existing 325sqm office floor area due to its simple, yet innovative trackless design – the mobile solution from SSI Schaefer offered an alternative approach during the tendering process.Vince Chiverton, Retained Property Projects Premises Officer, Nottinghamshire Police, said: “SSI Schaefer’s trackless mobile shelving system was the perfect solution for our storage requirements – as it has enabled us to keep the existing floor at the same level – if we had opted for a traditional system, a false floor would have been necessary in order to accommodate the tracks, resulting in on-going disruption whilst increasing the height of existing doorways.“The new system now allows easy access to all of our material storage in a central location rather than being stored across several satellite sites.The trackless design also eliminated a number of health and safety aspects – without the number of traditional guide tracks and ramps normally associated with mobile shelving, the surrounding trackless mobile shelving environment becomes much safer – no trip hazard. In addition, the order picker selected by Nottinghamshire Police to access the upper level of material boxes, would have become unsteady over a ramp.SSI Schaefer designed the mobile bases to accommodate the extra wide shelving bays needed to optimally store five boxes along the length of each shelf and in doing so, the entire complement of boxes was accommodated within the existing office space – an impressive 80% increase in storage capacity has been achieved by installing a trackless and mobile shelving system.A trackless mobile shelving system is ideal for businesses looking to increase existing storage capacity with little disruption to on-going work and minimum installation damage – only one rear guide track needs to be fitted leaving floor coverings undamaged.Less prone to breakdown over traditional systems, a trackless system is quick and simple to install, providing an easy to clean, low maintenance, modern and compact storage facility that can be integrated onto any surface and relocated at any time with ease.Available in a variety of heights, depths and aisle widths, the trackless shelving system really is the perfect storage solution for many different sector areas. Due to its simple, yet streamlined design, it is particularly useful within general office, museum and archive environments whilst also being the ideal storage system for the cleanroom industry, notably those within the pharmaceutical, healthcare, chemical and research sectors. Fitted with wheels at the base of each shelving unit, SSI Schaefer’s trackless mobile shelving significantly reduces the immediate load impact on the floor – a significant advantage when installing directly onto a raised access floor.

SSI SCHAEFER at Hannover Messe 2012

Fri, 30 Mar 2012 09:05:00 +0200

For this year‘s Hannover Messe, SSI Schaefer is going to present some highlights from its comprehensive product range on 400 sqm of floor space. The exhibits include plastic containers, automated systems, mobile shelving systems and logistics software.The range of containers is represented by SSI Schaefer’s new QX container for the automotive industry. The container is first and foremost supposed to work in combination with thermoformed blister inlays, able to hold car components. Also, it is highly automatable and complies with modern regulations on cleanliness in industrial assembly. The Euro light container is a real all-rounder for manual and automatic handling, with an extremely low self-weight.The innovative conveying and sorting system Fulfilment Factory is the result of merging the intralogistics processes of B2C and store deliveries into one facility. It is possible to customize the Fulfilment Factory with regard to throughput, share of delivery channels, amount and structure of orders across industries, always putting the logistical requirements of the user first. As a result of taking over Handler A/S, SSI Schaefer added the storage lift LogiMat to its range of products. This automated warehouse solution based on the vertical principle is certainly going to draw a lot of attention. It is particularly suitable for storing small parts and picking them ergonomically. What’s more, the LogiMat saves 90% of floor space compared with standard (static) storage systems and cuts travel times by more than 70%.The ELX mobile shelving system for light and medium loads is now available in an electrically powered version. Compared to the manual variant, the electrical mobile shelving system is moved by single motor-drive mechanisms. This enables rapid, safe and effortless operations, even with loads of up to 2 x 8 tonnes. Another novelty: Commands to access the system as a whole and to open individual aisles are transmitted by RFID technology. In Hanover, SSI Schaefer is also going to present its knowhow in software: WAMAS und SAP. WAMAS manages, controls and optimizes the entire spectrum of logistical processes in manual and automatic warehouses. WAMAS is a solutions that SSI Schaefer has already installed many times, because it can adjust to the most complex warehouse environments and remains flexible. Since November 2011, SSI Schaefer is officially a SAP service partner. This means, SSI Schaefer supports and advises global players as well as SME in choosing, implementing and maintaining an individual SAP EWM solution. Thanks to the competence of SSI Schaefer, the customer has access to the most advanced IT solutions available.

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.

System planning without data

Mon, 21 Nov 2011 10:09:00 +0100

New Wave CZ, Czech member of the Karel Holoubek Trade Group, sells qualityproducts in the paper goods and giftware market. The company ships orders within the shortest possible time to shopping centres, department stores, gift boutiques, toy shops, etc. in the Czech Republic and Slovakia. With the objective of increasing productivity, reducing labour costs and cutting picking times, the company placed their trust in SSI Schaefer in Graz and the Czech Republic to set up their distribution centre in Karlovy Vary.A lack of reliable and transparent transaction data previously hampered the company in tracking and efficiently compiling and shipping stocks of stored and picked goods on time. New Wave had also been picking goods entirely manually. This posed particular challenges as SSI Schaefer was not able to access any reliable data to base the new logistics concept on. Nevertheless, the intralogistics specialist delivered a highly sophisticated solution that contributed significantly to the success of New Wave, introducing automated technologies, software solutions and the delivery of all components from one source.The heart of the new system is a 5-aisle, automated small parts storage system with 35,000 container storage spaces. Here the Schaefer Miniload Crane (SMC) storage and retrieval system ensures efficient inward and outward goods movements. The Warehouse Management System (WMS) WAMAS controls all the processes. When a customer submits an order, the WMS processes it and starts picking the goods. In the outward movement, the SMC retrieves the load carriers and delivers them to a transfer zone. From here they travel via conveyors to the pick-to-tote workstations, where employees pick the goods according to the goods-to-man principle. Once again, a conveyor belt acts as a transport system conveying the goods to the dispatch station and preparing them for speedy dispatch.“SSI Schaefer presented us with a concept for a fully automated warehouse using the goods-to-man principle. The solution was new to us, but proved to offer exceptionally high performance. It enabled us to increase our efficiency significantly and to optimise warehouse capacity”, reflects Mr Dusan Materna, CEO at New Wave. “The company now has an extremely advanced and highperformance logistics centre.”

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.

The end customer strategy

Wed, 28 Sep 2011 15:52:00 +0200

Until now, three SSI Schaefer subsidiaries have stood for complex automated solutions: SSI Schaefer Noell, SSI Schaefer Peem and Salomon Automation. And it will stay this way. Nevertheless, the intralogistics specialist has decided to expand its range of offerings even further. With the new “Automatedtotal systems” sales department, the company headquarters in the Siegerland region is now also dedicated to automation.With the new department, SSI Schaefer caters to the needs of medium-sized companies finding themselves between two worlds, with a particular question: Manual system or an automated solution? Whereas the subsidiaries primarily realise complex, larger projects, SSI Schaefer, Neunkirchen offers semiautomated solutions as well as automated total solutions for medium-sized companies. Above all, the offer is specifically tailored to the end customer.This way, SSI Schaefer is providing its customers with even more comprehensive consulting as well as customised solutions. Always with the objective of increasing efficiency.

SSI Schaefer's Shelving System Serving Science

Wed, 08 Jun 2011 16:23:00 +0200

An exceptional system solution with high aesthetic and conservation requirements. System sections with glass bases and glazed front panels underline a level of solutions expertise extending far beyond standard components.They are the backbone of scientific research into the natural world: The collections of specimens at natural history museums. With around 30 million objects, the Museum of Natural History in Berlin possesses one of the most important collections in the world.As the gradual re-design of the museum landscape in Berlin was begun after the fall of the wall, plans were started for renovating the Museum of Natural History. The aim was to store a large proportion of the preserved specimens in the east wing under optimal climatic conditions. Right from the start, attention was paid to making selected examples of the fish and reptile collection accessible to museum visitors. “We needed an innovative solution for storage and presentation that met the high functional and aesthetic requirements. Flexibility in the customised design and safety requirements with regard to fire protection and ventilation also needed to be assured”, explains Dr. Peter Bartsch, responsible Head of Department and Curator of the collection at the Museum of Natural History in Berlin. SSI Schaefer, Neunkirchen was awarded the contract for this challenging project.Based on the R 3000 modular shelving system, the intralogistics specialist designed an optimal, tailored platform system solution using accessories primarily from standard elements. “Everything else is the result of longtest runs and new developments, from the glass design through to the shelves”, explains Klaus Muhl, Project Manager at SSI Schaefer. To achieve this, the building space of over 6 m in places was divided into 3 levels. The basic area of the 3 storeys totals around 1,150 m². A 2-storey racking system modified specifically for the space and the purpose is installed on each level.Around 1 million objects in the zoological collection are housed in the new collections store. It includes around 260,000 glass containers alone, preserved in 81,000 litres of alcohol.The east wing has been open to the general public since September 2010. Almost a third of the liquid specimens are exhibited there. To facilitate this, the ground floor has been fitted with an allglass display area. In a controlled tour through more than 300 m² of exhibition space, visitors can view rare specimens, some of which are of inestimable scientific and cultural value.Dr. Bartsch: “SSI Schaefer invested considerable development work to install an optimum solution incorporating aesthetic, conservation and technical fire safety considerations. The new collection store is an additional showcase area that will keep more scientists and visitors interested in our museum.”

Machine Vision Technology

Tue, 31 May 2011 08:09:00 +0200

SSI Schaefer extends in-house IT system expertise to include machine vision technology. Customers stand to gain from the technological benefits of industrial image processing in automation, quality checks through innovative product developments and use of fewer interfaces. SSI Schaefer is continuing to build on its IT development integration expertise in industrial image processing. Its overall objective is to identify and tap into new logistical uses for what is known as machine vision technology. “We have been working with machine vision technology for more than four years now and have already developed numerous innovations for automated order picking, sequencing and quality assurance by combining our expertise in this mechanical vision, machine control and logistical applications for our customers,” explains Dr. Max Winkler, head of development at SSI Schaefer. “We now boast extensive in-house know-how in all three fields which is unique in the sector. As a technology leader in intralogistics, we will use this to generate new system functionalities with new developments and produce additional added-value for our customers.”Industrial image processing is now one of the key technologies in automation. Its use in the pharmaceutical and automotive industry has become standard practice when checking components critical to safety. Machine vision technology can be used for tasks such as intelligently controlling machines, automating processes and verifying and checking components and items. Corresponding systems also check quality criteria and provide valuable data for process optimisation. The technology can therefore potentially be used in industrial production and intralogistics for tasks ranging from fully automatic palleting and depalleting, through sequence, position and orientation checks to quality assurance including complete documentation and traceability.Using machine vision technology, SSI Schaefer has now implemented system concepts such as Schaefer Case Picking (SCP), the Order Verifier and the Schaefer Robo-Pick (SRP). Integrated image processing makes e.g. the Robo-Pick and SSI Order Verifier the fastest fully automatic order-picking systems in their market sectors. The various image processing systems in the Schaefer Case Picking concept make distribution centres possible which deliver a customised mix of products fully automatically. Machine vision allows robots to fully exploit their goods distribution performance, thereby relieving staff of the arduous task of pallet order picking. For the user, this translates into efficiently automated and monitored production processes. Quality assurance and order picking become an integrated process, resulting in minimised error rates and greatly reduced staffing, energy and freight costs. The potential savings ensure a rapid return on investment (ROI).Another benefit of SSI Schaefer image processing technologies is that they are designed as independent subsystems with a flexible interface architecture, allowing them to be integrated in the intralogistics systems supplied by SSI Schaefer in many different ways. Not only can the systems be smoothly integrated into existing structures, they can also be quickly and conveniently adapted to modified production processes and model changes.The intelligent teach-in feature of machine vision technology from SSI Schaefer eliminates any lengthy teaching phase for the products to be handled. A larger range of products can thereby be flexibly detected. And the technology is perfectly aligned to the requirements of production logistics and intralogistics. Appropriately equipped systems are, for example, perfectly suited to rapid, complex automation and test tasks, ensuring less downtime, better process stability and great efficiency in the use of resources.By further extending its development and integration expertise in machine vision technology, the SSI Schaefer Group is now able to offer customers the linkage they need between software, intralogistics hardware and industrial image processing from one source. “SSI Schaefer has added an important future-focused technology to its range of products and services,” sums up Dr. Winkler. “By individually tailoring the technology to customer specific applications, we can produce numerous options for intelligently automated processes, improved quality, greater reliability and improved process reliability and economic viability.”

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.

WAMAS, miniload and sorter technology in perfect interaction

Thu, 26 May 2011 08:05:00 +0200

For Desigual, the SSI Schaefer Group has implemented an order picking solution with maximum efficiency in the smallest possible space. Result: An award-winning material flow concept that ensures individual fashion pieces are available around the world in every size, colour option and in every shop.The Desigual company founded in 1984, headquartered in Barcelona, sells 10 million items of clothing worldwide each year in over 5,000 shops. From Barcelona to New York, from Tokyo to Singapore, the fashion label offers a world of experiences for creative non-conformists and over 1,000 new designs each season.The decision to enter into a partnership with Salomon Automation has opened up whole new options for Desigual. The perfectly coordinated logistics solution from the general contractor, consisting of an order picking and conveyor technology system and a miniload has proved an outstanding success.The world of fashion offers at least two collections each year. These campaigns relate to the seasonally based initial stocking of the shops for the start of the relevant season and are planned and scheduled months in advance of shipment.The high total volume of clothing items is delivered from the production to the distribution centres gradually over a period of weeks. To be able to process the goods efficiently and ship them promptly, Desigual needs to start the order picking process for the orders as early as the inward storage process for the first articles. At the same time, re-orders are coming in on an ongoing basis to restock sold articles in the shops. Re-orders have a lower delivery volume per order and demand minimal throughput times. An optimal order picking solution therefore needs to efficiently combine these two processes.Salomon Automation developed an innovative order picking method in the form of a sorter chute combination modified specifically for processes in the textile trade that copes with the enormous expansion speed of Desigual.The key difference with regard to other well-known systems lies in the automated design of the sorter destinations combined with a split tray sorter process: The sort destinations are designed as chutes in this system and are installed directly underneath the sorter. The customer cartons are dynamically fed into the chutes using the WAMAS logistics software in the correct sequence for emptying. Using this system, Desigual achieves 4,000 orders at 54 physical destinations.At two ergonomically designed order picking workstations, 3,600 items of clothing per hour and workstation are order-picked from the open source cartons onto the sorter feed. What is known as an automatic infeed belt is used here as “breathing space” between order picker and sorter, meaning that staff members are not hindered in their work. The conveyor technology was installed by SSI Schaefer, Graz.The sorter distributes the goods into two exactly sorted stacks on 54 intermediate chutes which drop off the parts with precision following automatic inward transport of the relevant customer cartons. The sometimes partially filled cartons are conveyed automatically into the highly dynamic, 3-aisle miniload intermediate buffer storage with 5,400 storage spaces. This was modified specifically to the height of open cartons by SSI Schaefer, Neunkirchen. In the integrated 6-aisle tray warehouse with 90,000 storage spaces, the target and source cartons are managed with a total of 3 million single items by WAMAS.“We are able to deliver 100,000 items of clothing per day and thanks to our automated warehouse we can store up to 3 million items and process 5,000 orders. We also deliver efficiently around the clock”, reflects Desigual on the new logistics. The solution has been awarded two renowned prizes, the “ICIL Foundation” and the “CEL – Centro Español de Logístico”.

New high bay warehouse for Müller Ltd. & Co. KG

Mon, 18 Apr 2011 16:17:00 +0200

On an area the size of 5 football fields, Müller Ltd. & Co. KG has opened a massive logistics centre not far from the company‘s headquarters in Ulm, Germany.With SSI Schaefer, Neunkirchen, as their partner for the steelwork construction of the pallet and container order picking system, Müller is again relying on the expertise of the specialists in high bay racking systems. The installation was scheduled for completion at the start of 2011.As an international company, Müller has over 600 sites across Europe. New sites opening every year are the reason for the continual ongoing development of the company in Germany and abroad. The actual product offering is reflected in the wide range of outlets where customers can find a wide range of products including beauty products and over-the-counter medicines, perfumes, stationery, games, household items as well as textiles and multimedia products.Supplying all outlets as needed and on time is the challenge presented for a perfect logistics system. For this system to cope with the company‘s significant expansion, Müller made the decision to expand its warehouse capacities and as a result, to build the new logistics centre. The new building with its imposing external dimensions of 259 m in length and 104 m in width as well as concrete supports of heights of up to 35 m, has been designed to provide a highly compact storage and order picking system.The company IWL AG in Ulm began planning the large-scale project in the Summer of 2008. After completing the hall complex, SSI Schaefer began installing the steel framework in May 2010; initially for the high-bay pallet racking system with around 39,000 storage spaces. The system was put into operation just 5 months later, followed by the start of the 5-month construction phase for the container warehouse with around 170,000 storage spaces. To maintain the tight schedule for both warehouses, work was carried out in a 2-shift operation, 7 days a week. The task was the precision-fitting of around 7,000 tonnes of steel. To achieve this, up to 60 fitters were on-site simultaneously. Over 540 HGVs were required to transport the profiles manufactured in Neunkirchen, with a total length of over 800 km, to the construction site.The project was completed at the start of this year, and since then the logistics complex has created around 550 new jobs. Based on the three-way extension options incorporated, there are no limits set on the expansion of the logistics at the Ulm site, leaving space open for any future expansion of Müller’s network of outlets.

New central high bay warehouse for Fresenius Medical Care

Wed, 23 Mar 2011 08:32:00 +0100

At its site in St. Wendel, Fresenius Medical Care currently employs 1,700 people in developing and producing life-sustaining products for treating chronic kidney failure. St. Wendel is the main production facility for dialysers at Fresenius Medical Care.A distribution centre with around 4,900 m² of space, replacing several smaller storage sites inside and outside the factory premises, will be raised there before autumn 2012. At the core of the new facility will be a high bay warehouse with almost 30,000 pallet storage positions for storing both products for dialysis and their required raw materials. The warehouse will be constructed as a silo, measuring 115 m in length, 45 m in width and 35 m in height. In six aisles and on 13 levels, the storage space will be temperature-controlled between 16°C and 25°C. The loading bay, additional storage space, utility rooms and offices will be located in a three-storey logistics building designed as a solid construction.“Resulting from an increase in production capacity and raising demand for our dialysis products, we are in need of a modern, central high bay warehouse.” explains plant manager Ulrich Kramp. “This way, we will be concentrating the storage of finished goods and raw materials in close proximity to the production. This is going to improve coordination between production and sales, while also lowering costs for transportation. Modern facilities with their high degree of automation assure a rational and precisely timed internal flow of materials. Design and dimensions of the warehouse will facilitate further growth and allow for increases in the plant’s capacities.”With this assignment, SSI Schaefer is once more emphasising its leading position in complex system solutions.

The ECOtech foldable container in the spotlight

Wed, 16 Mar 2011 14:02:00 +0100

Our engineers did an outstanding job developing the ECOtech. We are therefore happy to see this container get the appreciation it deserves. It won the award in the category storage and transport systems because the jury recognised its design, innovation and functionality.The association had summoned 13 experts to judge all the contestants and they finally voted in favour of the ECOtech container. Ralf Olsen, director of pro-K, was pleased to come in person to present SSI Schaefer with the award certificate.SSI Schaefer offers this foldable container in two versions, either with closed side walls or with one or two display flaps on the front side. With these flaps, access to the content is possible even when the containers are stacked.Another notable characteristic of the ECOtech is the reduction in volume when folded down. It amounts to about 80% and the folding is done quickly, safely, and without sequential order.These obvious advantages make this new container a great choice for a number of applications in industry, trade and services. In addition, it is suitable for automation and can be used in an automated small parts storage system with conveyor technology. There was a general consensus that the ECOtech foldable container by SSI Schaefer represents a convincing and innovative improvement over existing storage and transport systems.

SSI Schäfer takes over Handler A/S

Wed, 02 Mar 2011 09:52:00 +0100

With more than 2,500 references, Handler A/S occupies a strong market position in the storage lift segment, particularly in the Scandinavian region. With the integration of the Danish company, SSI Schäfer completes its product chain as a full-service provider for intralogistics. Owing to the practically complete coverage of value creation at the SSI Schäfer Group, it is expected that significant synergy potentials in production, distribution, project management as well as in customer service & support will be achieved. The LogiMat® storage lift is considered future-oriented and extremely operator-friendly. Thanks to the ergonomically conceived components, the LogiMat® integrates seamlessly into the SSI Schäfer product range Ergonomics@Work®. Stepless, height-adjustable access openings and incline devices on the trays for the ergonomically correct removal of goods are just two examples from the fully-equipped equipment package. We can also take economic efficiency into account, thanks to the compact storage and modular design of the LogiMat®. Compared to a common static storage solution, the storage lift only requires 1/10 of the storage space. The clever SPS control can be supplemented by the in-house software package Wamas® and/or integrated seamlessly into the existing inventory management system. Various options for an increase of efficiency and maximum optimisation of the picking speed complete the package.SSI Schäfer will present the LogiMat® storage lift for the first time in May 2011 at the CeMat in Hannover.