SSI SCHÄFER News

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.

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."

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.

WAMAS Warehouse Management Software for Automated Logistics Centre

Tue, 20 Nov 2012 14:15:00 +0100

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.

Fulfilment Factory: maximum efficiency for all sales channels

Wed, 11 Jul 2012 12:12:00 +0200

Via the integral “Fulfilment Factory” concept, SSI Schaefer is offering a totally new product for combined order processing for various sales channels. The newly developed individual product conveyor and sorting technology will merge intralogistics for supplies to end customers (B2C) and store and wholesale business (B2B) in one integrated process. A patent application for this concept has already been filed. The Fulfilment Factory concept can be tailored flexibly to the user’s logistical requirements across all sectors in terms of range of items, production volumes, spread over various sales channels and type and structure of picking orders. Another special feature of the new development is that it is the first to allow batch-picking, product sorting and order consolidation to be cost-effectively combined following the “goods to man” principle. The Fulfilment Factory is a modular concept including warehousing, ergonomically and logistically optimised batch order picking, a totally new, space saving conveyor module and efficient buffering and sorting of batch items, as well as workstations for the integrated process of order assignment, packing and a link to shipment with a shipment buffer as an available option. Manufacturers and retailers optimise the sale of goods by continually expanding various sales channels. Customers increasingly have the choice of whether they want to purchase items in a shop or remotely. This is a huge challenge for distribution centres because the logistics requirements and features of supplying end customers and stores/wholesale are very different. B2B processes involve periodic delivery cycles, 20 to 500 order lines with up to 100 items per line and a targeted number of delivery addresses. The B2C sector is characterised by rapid, ad-hoc deliveries of small quantities at short notice with single-figure order lines each containing up to five items. However, the spread and increase between the various sales channels is getting harder to plan and consequently requires a lot of distribution flexibility. In the past, processing these orders simultaneously greatly limited resource efficiency because of separate storage locations or order-picking areas for the corresponding sales channels, therefore compromising process efficiency.The Fulfilment Factory from SSI Schaefer is the first integral, yet modular system to combine high efficiency with new levels of flexibility. By using standardised system components and a special carrier system, the new development enables both individual products and item quantities to be conveyed in integral system technology. The Fulfilment Factory concept is also perfectly suited to returns processes which have become a very large part of distribution logistics.Batch order picking coupled with sorting at individual item levels is the most efficient and also the most flexible way of operating a goods distribution warehouse. In the past, the system technology required for this was so complex and expensive that it was not cost effective to use. The Fulfilment Factory from SSI Schaefer is therefore not only a technological breakthrough but a financial one as well. It delivers maximum efficiency and flexibility for a variety of sales channels.

LIDL plockar med SSI Schäfers Case Picking-system

Fri, 22 Jun 2012 12:00:00 +0200

SSI Schäfer har utvecklat livsmedelskedjan LIDLS logistikcentral i Kirchheim/Teck med ett helautomatiserat plocksystem. Leveransavtalet omfattar ett Schäfer Case Picking (SCP) System ett höglager med fem gångar och ca 15 000 pallplatser samt ett Schäfer Tray System (STS) med 16 000 förvaringsplatser i fem nivåer. Systemet optimerar automatiskt pallhanteringen vilket ger säkra transporter och effektiviserar påfyllningen av butikerna. Projektet fortgår enligt plan och befinner sig för närvarande i slutet av uppstartningsfasen. Idag får 75 % av butikerna sina varor från Kirchheim/Teck med butiksanpassade blandpallar. Planerat slutdatum för projektet är sommaren 2012. Förutom den smidiga hanteringen av denna modulbaserade, skalbara och i princip obegränsat utbyggbara lösning uppskattar LIDL särskilt det välfungerande och målorienterade samarbetet med SSI Schäfer.

Lighter by design – the new Euro light container (ELB)

Thu, 26 Apr 2012 12:03:00 +0200

SSI Schaefer has continuously grown its know-how in container design by using the latest technologies, intensive cooperation with customers and many years of experience. Now, the intralogistics specialist translated all this knowledge from special applications into a high tech product for daily use: the Euro light container. Developed with new material and tool technology, the stackable ELB is a very affordable, stable all-round container with a surprisingly low self-weight. Different versions allow loads of 20 – 50 kg, depending on the base variants.Thanks to its vertical side walls, the inner volume of the container is fully usable. In addition, the specially designed corner posts facilitate high stacking loads and easy cleaning of the container. The ergonomically shaped grip openings on both face ends permit uncomplicated handling. Whether it is used for everyday purposes or inside a warehouse, owing to the container’s characteristics, the number of possible applications is almost unlimited.

Sophisticated Order Picking Strategies

Tue, 02 Oct 2012 10:57:00 +0200

From the customers point of view, delivery reliability and quick reaction times are two main criteria for quality logistics services. Intelligent storage and distribution systems ensure the quality of logistic services. The best intra-logistic technology cannot deliver if sub-standard warehouse structures limit the quality of logistic services and shuttle transports between warehouses and unnecessary repeat-handling are in use. This being the case, the Danish retailer, Coop Danmark A/S, decided to restructure and reconfigure their logistics in 2008. Seven regional warehouses were to be combined into one central warehouse in Odense, Denmark, equipped with state-of-the-art order picking processes. After an international invitation to tender, the contract for designing a suitable logistics concept as well as the turn-key creation of the logistics center from constructing to furnishing a high bay warehouse and the installation of an individually tailored warehouse management system (WMS) was awarded to the intra-logistic specialists of SSI Schaefer in Giebelstadt, Germany. "In view of our diverse product range, we were looking for a solution with intelligent material flow and well-defined order picking strategies", explains John Møller, warehouse manager at Coop. "SSI Schaefer offered the best solution for our requirements along with an ideal price/performance ratio".Coop Danmark A/S has more than 9,000 non-food-items in store – from TVs to video games and clothing. They supply approximately 800 supermarkets throughout Denmark, the Faroe Islands and Greenland. Coop Danmark A/S is Denmark’s largest retailer of fast moving consumer goods. The company operates the retail chains Kvickly, SuperBrugsen, Dagli'Brugsen, LokalBrugsen and the subsidiaries Fakta A/S and Irma A/S and is owned by FDB. Together with the co-operative societies the company has an annual turnover of approximately DKK 50 billion and has 1,200 stores all over Denmark. The company has approximately 35,000 employees in total. Many of the products are items from advertising campaigns which have to be supplied to all stores at a particular time. Since January 2010 supply takes place from the new central warehouse in Odense. For exactly this purpose, the three-block high bay warehouse (HBW) with four aisles per block and a total of over 36.000 storage locations for single-deep storage of pallets that may weigh up to 1.000 kilogram was constructed by SSI Schaefer. The high bay warehouse (HBL) started running in the beginning of April 2010. Altogether twelve storage and retrieval machines that move at a speed of up to 250 meters per minute ensure quick storage and retrieval of more than 500 pallets per hour. The HBW serves as a supply and transfer warehouse.Parallel to the high bay warehouse, SSI Schaefer created the warehouse management system for the manual low-bay warehouse. There, storing positions for man-to-goods order picking of fast-moving items are available across three shelf levels. "Stock and processes at the warehouse in Odense are governed according to advertising campaigns" explains Peter Lambrecht, project manager for SSI Schaefer. "The objective is to achieve a high throughput in a short time. In addition there are also finishing treatments that take place at the logistic center. Due to the complex product line, different types of storage areas as well as several different order picking strategies characterize the flow of goods at the Coop logistic center."Coop does not necessarily achieve topmost flexibility through maximum automation. Due to the complex product line, order picking strategies are in fact vastly oriented toward the efficiency of manual processes.Items delivered on pallets are logged in goods receiving and transferred to the high bay warehouse or block storage. Articles like Playstations, which will have CDs added, will be allocated to the workstations immediately and when required. After the addition, they are 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 like CDs that are not large enough to be picked directly from the pallet. Both systems are supplied from the high bay warehouse or as the case may be the manual warehouse – depending on the advertising campaign. "Supply of order picking positions and the picking process itself are controlled by the WMS 'ant' designed by SSI Schaefer", informs Lambrecht. "Particularly due to the varied order picking strategies that Coop pursues in Odense, this project was a special challenge for our IT department."Up to 25.000 order lines for just under 600 orders are processed daily at Coops central warehouse. Depending on the items in the order and the advertising campaign, five partially linked order picking strategies are designated for this task. Thus, each of the three HBW blocks is equipped with a picking station to palletize items for large orders. Two people can be assigned to each station. Controlled by the WMS, source pallets are retrieved from the high bay warehouse and allocated for order picking at six source positions of each block. There, supported by height adjustable, ergonomically designed working platforms, items are picked from the source pallets onto seven target pallets. Therefore, the six people assigned to order picking can process 21 order pallets. This takes place in three stages. Hence, an hourly output of up to 60 readily picked pallets can be achieved in this area.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 the commissioned work is complete and after automatic load securing took place, they may be forwarded directly to the three dispatch areas via the conveyor system and installed lift systems. Parallel to this, the WMS arranges for the disposal of packaging waste. The waste 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" explains 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 equipped with a Pick-by-Light-System. Pallets containing items ordered by many shops that have to be pre-picked are supplied from the high bay warehouse."With operating units designed especially for this application, pallets can be brought to the ergonomically ideal height" says Møller. "In Denmark strict guidelines for ergonomics and occupational safety are in place." 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 has been completed, the order picker generates a label for each box and applies it to the outside of that box. Subsequently, the boxes are temporarily stored in the channels of the shelf system. In case the number of boxes exceeds the capacity of a channel, a new channel will be assigned."Once picking for a specific shop in the large consignment area is complete and this shop also ordered goods of a pre-picked product group, a box from the shelf-channels is added to the shipping pallet," Møller comments on the subsequent steps of the process. While being transported on the conveyor system, ready-picked pallets pass through a wrapping station and are then 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 verifiably improved shipping package and safety for items as well as the preventive theft protection after the handover of goods", explains 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. Alongside small items of the shelf-system with gravity-roller-conveyor and the high-value items from the paternoster system, this especially applies to commodity groups from the block storage. There, the two top shelves are used as replenishment. Order picking is done from the pallets in the lowermost shelf. Pick-vehicles are in operation to support employees. Depending on product group and number of items, vehicles can be equipped with up to two roller container. That way, items for up to four different orders can be picked using optimized routes. Correspondingly the possible pick-strategies also vary. "Combined with material flow for storage and retrieval movements of goods received and pre-picked pallets in the high bay warehouse, the WMS has to control and monitor five types of order picking overall", states SSI Project Manager Lambrecht. "Moreover all goods movement with respective status are continuously booked and governed by the WMS." Furthermore, a visualization installed by SSI Schaefer offers continuous transparence. With an incorporated Gate Management program the IT department of SSI Schaefer also provides order and structure to the docking of trucks for loading and unloading."Ideal utilization of space, high flexibility, reliable order processing - altogether SSI Schaefer designed a very efficient solution. Not only did it increase our throughput and process reliability but it also offers us capacities for further expansion of our business areas and activities," Coop Warehouse Manager Møller sums up. "Our expectations of the restructured logistics and the effectiveness of the new central warehouse were met with the system by SSI Schaefer."

SYSTEM RETROFIT PROJECTS FOR BUSINESS

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

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

Economically and ecologically effective

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

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

Seamless, future-oriented solution

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

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

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.

Ny Försäljningsdirektör hos SSI Schäfer

Mon, 06 Jun 2011 10:29:00 +0200

För att förstärka SSI Schäfer i Sverige startar Stefan Segerlund som ny Försäljningsdirektör hos SSI Schäfer Sverige den 1 Juni, 2011. Stefan har tidigare arbetat som Product Manager / Sales engineer vid Dynamic System i SSI Schäfer Schweiz. Stefan har ansvar för försäljning av MHE i Sverige samt att han sköter den operativa styrningen av Malmokontoret. Stefan ser fram emot att kunna utveckla den Svenska markanden och säger: Med en väldigt innehållsrik produktportfölj har SSI Schäfer möjligheten att tillfredsställa företags samtliga materialhanteringsbehov oavsett typ av gods, temperaturområde eller materialflöde. I hela Europa, samt även i Sverige, ser vi på SSI Schäfer en klar rörelse mot semi-automation samt full automatisering inom logistikbranchen, vilket aven kommer bli vårat fokus de nästkommande åren.

Machine Vision Technology

Tue, 31 May 2011 08:13:00 +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.”

SSI Schäfer och de fem kompetensområdena

Wed, 09 Mar 2011 11:07:00 +0100

SSI Schäfer har fått en ny hemsida. När SSI Schäfer beslutade sig för att skapa en ny hemsida blev en idé till verklighet. Det är vårt mål att visa företagsgruppen som den är – en enhet med ett gemensamt mål: Effektivitetsförbättrande lösningar till våra kunder!Användaren kan dyka in i SSI Schäfers värld i det serviceorienterade, informativa och estetiskt tilltalande virtuella rummet. Därmed har det uppstått en helhetslösning som rör sig på en ny nivå beträffande kvaliteten. Under profilen SSI Schäfer finns företagets samlade kompetens inom fem områden: Logistiksystem, Lager & transport, Arbetsplats, Logistiksoftware samt Avfallsteknik. Med den nya hemsidan får profilen och företagets struktur ett passande ansikte utåt. Intressanta detaljer som film, digitala broschyrer, nyheter, online-anmälningar till evenemang, entrébiljetter till mässor och kontaktmöjligheter erbjuder besökare på sidan mer än bara hjälpsam information. Istället får de en omfattande service som ger inblick i verksamhetens samlade produktprogram i alla avseenden. Här blir på ett och samma ställe åskådliggjort vad som är utmärkande för SSI Schäfer som specialist inom intern logistik. Mer än 70 års erfarenhet av lagerlogistik. Mer än 35 års erfarenhet av avfallsteknik. 16 produktionsenheter på 3 kontinenter. Representerat världen över i mer än 50 länder. Det finns många vägar som leder till målet, och som ingen annan verksamhet har SSI Schäfer möjlighet att välja den mest effektiva lösningen och realisera den som totalleverantör. Därför har verksamheten valt ut ett rött E som det tecken som förmedlar kärnbudskapet: Du ökar din framgång för att vi ökar din Effektivitet!

SSI Schäfer tar över Handler A/S

Wed, 02 Mar 2011 08:22:00 +0100

Med sina mer än 2 500 kundreferenser innehar Handler A/S en stark marknadsposition inom lagerautomater, särskilt i Skandinavien. I och med införlivandet av det danska företaget kompletterar SSI Schäfer sitt produktprogram som totalleverantör av intralogistiktjänster. Tack vare det värdeskapande arbete som kännetecknar SSI Schäfer-gruppen förväntas förvärvet medföra avsevärda synergimöjligheter ifråga om tillverkning, distribution, slutförande av projekt samt kundtjänst och support. Hissautomaten LogiMat® betraktas som banbrytande och ytterst användarvänlig. Tack vare de ergonomiskt utformade komponenterna passar LogiMat® helt perfekt in i SSI Schäfers produktprogram Ergonomics@Work®. Steglöst höjdreglerbara betjäningsluckor samt hyllor som kan lutas för en ergonomiskt optimal hantering av material är två exempel på det omfattande utrustningspaketet. Tack vare sin kompakta lagring och modulära konstruktion drar även lönsamheten stor nytta av LogiMat®. Jämfört med en vanlig, statisk lagerlösning tar lagerhissen endast 10 % av lagerytan i anspråk. Den avancerade SPS-styrningen kan utökas med vårt eget LogiSoft-mjukvarupaket samt/eller integreras i nuvarande varuhanteringssystem. Diverse valmöjligheter för ökad effektivitet samt maximal optimering av plockhastigheten avrundar paketet.SSI Schäfer presenterar lagerhissen LogiMat® för första gången offentligt i samband med CeMat-mässan i Hannover i maj 2011.

Schaefer Robo Pick voted “Best Product 2011“

Mon, 07 Feb 2011 08:19:00 +0100

For the 8th time already, representatives from business, science and media thoroughly evaluated the line-up of contestants prior to the LogiMAT 2011. Awards were given to products which contribute significantly to streamlining, reducing costs and increasing productivity in intralogistics. The Schaefer Robo Pick by SSI Schaefer Peem won the award “Best Product 2011“.The SRP is the world’s fastest picking system and able to pick goods of different sizes, shapes and weight at a speed of 2,400 items/hour, while working error-free and gentle on the products. This first fully-automated picking cell can be integrated smoothly into existing storage systems. With its newly developed double-stage image processing system – a combination of procedures from 2D and 3D image processing – it does not require any time-consuming teach-in of product parameters or position. The degree of flexibility achieved this way is unique and makes the SSI Schaefer Robo Pick suitable for a broad range of applications. The image processing cell takes less than one second to realise the position of a product on the tray and then operates the universal picking robot accordingly. Depending on the order structure, 10 to 20 orders can be handled simultaneously. In comparison to manual picking, this system reduces error rates by a factor of 10 to 100.Procedure: In a typical order picking process, a conveyor delivers containers with sorted products to the Robo Pick. By using 2D- and 3D-cameras, the exact position, height and centre of area are detected with double-stage image processing. Specifically developed image processing software recognizes continuous shapes and edges within a fraction of a second. After image recognition, the subsequent robot receives its orders. Within seconds, the robot places the requested products into order containers, based on requests from the warehouse management system. Goods of different sizes, shapes or surface texture are picked up gently by a vacuum gripper. For further information about the Schaefer Robo-Pick, please download our brochure.

First Logistics Service Provider to use the ECO-tech Foldable Container

Mon, 07 Mar 2011 08:14:00 +0100

Collico is one of the market leaders in the pooling of reusable containers and was established in 1947. As a 100% subsidiary of DSV – a global service provider for transport and logistics, running a network of partners for professional solutions in more than 110 countries – the company offers Europe-wide services for reusable packaging.“We expect considerable reductions in costs by switching to the ECO-tech container. This container is incredibly easy to handle. Folding and expanding is done quickly and safely, almost off the cuff. This saves quite a lot of time and money.“ according to Peter Köhler, CEO at Collico. “Our customers will also appreciate these advantages.“He is certain, that using the container within a supply chain will provide additional benefits, because it is suitable for conveying and automated small parts warehouses. The container also provides protection against theft with its closed side walls and added value with its low weight, but without compromising stability. „We are working with customers from different industry sectors, for example retail, mail order business, automotive industry and chemicals. This container is suitable for any industry and also very environmentally friendly. I think it’s the most innovative reducible container on the market right now.“

Lean Intralogistics for highly efficient Distribution Centres

Mon, 07 Mar 2011 07:23:00 +0100

The SSI Schaefer Group developed a tailored solution for the logistics centre of contract service provider Baur Fulfillment Solutions GmbH (BFS), Weismain, to solve a challenging intralogistics problem. The result is a multi-storey platform system providing storage space for almost 350 000 storage locations. New processing stations and an ingenious material flow concept with compact conveyor technology ensure efficient processes and a 15 % boost in productivity.This just goes to show that big automation solutions aren‘t always needed for high throughputs. SSI Schaefer produced an efficient storage solution for Baur, a subsidiary of the Otto Group, using a concept involving racking systems and conveyor technology in an existing building.With 15 million customer contacts a year, 40 million shipments and 100 million goods movements in a storage space of around 250 000 m², BFS ranks 5th amongst fulfilment service providers with similar process chains. An average of 7 million individual parts are finished if necessary, order picked and dispatched for mail order companies, retailers and brand manufacturers. 18 million items and 8 million returns are processed by staff at the site every year.The existing logistics structures were no longer able to cope with these requirements and the continual growth in orders. At ground level the 12 m high hall was simply being used as a pallet depot. “So we decided to use the entire height of the storage hall, equip the entire hall out for handling goods and concentrate our storage, finishing and handling of returned goods,” explains BFS Managing Director Jürgen Lehmann. An efficient material flow needed to be developed quickly and reliably and implemented in the existing building structure.“We envisaged a solution with a freestanding, self-supporting platform design. The 3 levels and in some places 4 levels are served using space-saving conveyor technology which is adapted to the platform design,” explains Rainer Lautz, project manager for racking systems at SSI Schaefer. A racking system of a size never before produced was built within 4 months. It comprises 67 000 m of uprights and more than 65 000 shelves.The platform levels and racking systems generated an area of 19 500 m², offering storage locations for around 350 000 standard cartons and containers. Around 2.5 km of conveyor technology, roller and belt conveyors and transfer tables connect the different levels and newly set up and linked packing, returns and preparation stations. A load lift was installed in addition to the staircases to allow staff to work on the different levels which are arranged to allow for order picking on all floors.Since the hall was already in use, SSI Schaefer had to take into account around 100 supporting columns and optimally adapt the flow of material when designing the site‘s conveyor technology.“The solution has increased productivity by 15 %,” sums up BFS management spokesman Danilo Georg. “The lean conveyor technology means that 15 – 20 % fewer storage locations were lost than with comparable solutions put forward by other bidders. The platform design and racking systems have increased our storage location capacity much more than we thought they would. And SSI Schaefer completed the job faster than planned too. A truly exemplary project.”

Collapsible Container “ECOtech” voted Product of the Year 2011

Tue, 14 Feb 2012 11:50:00 +0100

For 30 years, the industry association for semi-finished and consumer products is awarding the title “Product of the Year” to innovative, creative and functionally outstanding products. In this year’s competition, the ECOtech container prevailed against numerous contestants, judged by a competent jury consisting of 13 members – among them scientists, designers, journalists and experts in quality control and consumer protection. This new line of containers for industrial application convinced the jury with innovation, superior design and functionality. As a collapsible container it can be used within an automated small parts warehouse and offers plenty of capabilities suitable for industry, trade and service. Quoting the jury: “The ECOtech is a convincing improvement over established storage and transport systems. Its new features, for example the display opening, are a testament to its innovative functionality.”The industrial collapsible container is available in two versions: with closed side walls or with one or two display flaps on the front side. The version featuring a display flap allows easy and safe access to the content of the container. Through this flap opening, the content can be reached comfortably even while the containers are stacked. The same holds true for filling the containers. This way, the picking capacity will increase and allow for an additional picking station in the same space. With integrated safety closure and ergonomically formed handles, this container can be collapsed quickly and safely without sequential order and realises a reduction in volume by 80 %.