Nuremberg (11/7/2014) – Since 2010, the Klinkhammer Group has been realizing and implementing various extensions of the intralogistics system at Marburg Wallcoverings. By implementing a fully-automated high bay warehouse section and a small parts warehouse, introducing a new intralogistics concept and installing new workstations in the shipping area, throughput times were minimized, ordering times reduced and transparency was increased.
The Marburger Tapetenfabrik (Marburg Wallcoverings) has more than 4,000 wallpapers in its range of products and thus is one of the leading wallpaper manufacturers worldwide. Founded in 1845, 169 years ago, Marburg Wallcoverings nowadays stands for creativity, innovation and reliability. All wallcoverings are exclusively “made in Germany”. The product range is supplied to more than 80 countries all over the globe. Being a full-line supplier, Marburg Wallcoverings offers quality wallpapers to suit any requirement, design object products made by artists like for example Harald Glööckler, Ulf Moritz or Luigi Colani and technical wallcoverings for industrial buildings and hotels.
New requirements ask for new concepts
While formerly large quantities were ordered, the customers nowadays order custom-fit quantities which they immediately pass on to the end user. Hence, also Marburg Wallcoverings assumes the role of a kind of intermediate storage for many of its retailers which has to serve the market in a highly flexible, rapid and reliable manner. The Klinkhammer Group headquartered in Nuremberg developed the intralogistics concept and implemented the system solution to meet this requirement. Since 2010, the Nuremberg-based independent automation and intralogistics experts have been taking care of the different sub-areas. The primary goal always stayed the same: reducing throughput times to a minimum, further cutting down the ordering- and delivery times and increasing transparency of the movements of goods by means of fully-automated solutions and processes. At the beginning of this year, the high-bay warehouse was enlarged by two aisles, thus increasing the capacity to 22,884 storage locations.
Efficient Distribution of Goods across High-Bay and Small-Parts Warehouse
The pallets with the goods packed in cardboard boxes leave the production area and are then transported directly to the high-bay warehouse via a conveyor bridge. Once arrived, the goods are distributed evenly and stored in the warehouse fully automatically. The dual load handling device with parallel replenishment unit guarantees maximum efficiency. When storing the goods in the warehouse, criteria such as sales frequency or production sequence are of essential importance, because many customers are seeking wallpapers which are identical in color, especially when reordering designer and exclusive wallcoverings. This data is stored in the Klinkhammer warehouse management system. This way, it is possible to store the goods such that the individual customer needs and the market and delivery conditions are met.
Logistics center as key element
The logistics center is situated at the front end of the newly built high-bay warehouse of Marburg Wallcoverings. It is the key element for all logistic processes. Here, 12 order picking stations have been built for picking goods from cardboard boxes. At each work station, the necessary picking information are provided by displays. Thanks to the cardboard boxes being clearly labelled right from the start, traceability at any time and on all levels is no problem. Once the consignment is ready for shipment, conveyors ensure that the orders are transported to the labelling station and finally to the different shipping areas. The labelling system has been certified for all large shipping companies such as Deutsche Post or UPS.
Considering even small quantities
Small orders, supplier samples, brochures or promotional products are retrieved from the adjacent automated small parts warehouse and then directed to the picking workplaces for small quantities. These workplaces as well are located in the logistics center in front of the high-bay warehouse. Here, products are repacked and automatically transported on to the next station. Deliveries containing complete orders are conveyed automatically to the i-point where forklift trucks transport them to the shipping zone.
Transparency right from the beginning
The Klinkhammer warehouse management software guarantees permanent and continuous transparency of all movements of the goods in the warehouse. The software registers the flow of incoming goods into the warehouse, arranges daily tours and merges them centrally in the logistics center. The software also ensures capturing the goods leaving the warehouse by scanning them. In the dispatch area, finally the single orders are documented by scanning them again shortly before loading. This way, all information are available at any time and company resources can be planned in the best way.
Shipping with more efficiency and reliability
In December 2014, Marburg Wallcoverings will again increase its dispatch quality in a further system section. The shipping area for mixed pallets will then be changed from 4 shipping stations so far to 26 individual workplaces. In the past, up to 6 pallets had to be picked at each station. Now a picking station is assigned to each pallet. This way, it is possible to process 26 orders simultaneously. For this new concept, the focus was placed on higher efficiency and reliability in order processing by means of a clear allocation. “Of course, the picking staff at Marburg Wallcoverings already now is guided intelligently via put-to-light. The new concept, however, and the single workplaces featuring touchscreens and scanners will make work even more easy”, explained Frank Klinkhammer, managing director of the Klinkhammer Group.
Data and Facts: The Klinkhammer system at one glance
- Pallet high-bay warehouse: 22,884 storage locations
- Automated small parts store: 15,360 containers, size: 600 x 400 mm
- Pallet conveyor technology:
- 7 pallet storage and retrieval cranes with double load handling device
- Around 300m of conveyors (including 2 lifts, 1 crossways transfer car)
- Container conveyor technology:
- 3 tote storage and retrieval cranes
- around 1,000 m of conveyors
- Material handling control computer (MHC) / Warehouse management system (WMS):
- MHC and WMS with DC21 Warehouse Management System
- Integrated radio data transmission system
- Visualization using ConVis
- Performance data:
- 12 power order picking stations: 150 pos/h, 500 full cardboard boxes/h;
- 6 small parts picking stations: 120 pos/h, 450 rolls/h;
- 1 return shipment station
- Shipping area: 20 full pallets/h, 620 individual cardboard boxes/h
- 26 mixed pallet stations