With an expansion and modern warehouse automatization, Simba Dickie Group, one of the leading toy manufacturers, optimizes its logistics at the logistics center in Sonneberg. Together with the intralogistics specialist Klinkhammer, Simba Dickie Group extends the existing automated small-parts warehouse by 4 aisles and an integrated order combination buffer as well as modern order picking stations, thereby setting a new course for future logistics processing in Sonneberg. The product portfolio of Simba Dickie Group comprises more than 4,000 toy products of more than 20 brands, such as Smoby, Big, Eichhorn, Majorette, Aquaplay, Schuco or Noris. Simba Dickie Group employs about 3,000 people worldwide at 30 locations.
The already existing automated small-parts warehouse containing 3 aisles is extended by 4 additional aisles and an integrated order combination buffer, thereby increasing storage capacity by 18,240 container storage locations. In the future, a total of 31,920 containers will be stored in the small-parts warehouse. An order combination buffer is integrated into the 7thaisle. The finished orders arriving through flow channels are passed on for shipment manually or by order picking trucks.
The existing order picking area is modified as well. A novel, ergonomic order picking concept will reduce error rates and simplify procedures and processes. At each workstation, up to 4 containers can be deposited onto two tables, enabling the simultaneous picking of 8 orders per i-point in a multi-order picking procedure. The shelf aisles can be accessed via a platform construction above the pre-zone conveyor technology, extending the existing platform. The conversion concept comprises 5 stages of construction, enabling the existing system to run uninterrupted during ongoing operations.
As part of the expansion, the warehouse management system is converted from SAP WM to SAP EWM. Together with its SAP-partner SWAN, Klinkhammer replaces the old software and brings it up to date. The existing visualization system is also extended by Klinkhammer. Due to the data exchange with the controls of the AS/RS and loading aids, the visualization system clearly shows all target data and the status of the loading units. Operating data is recorded and logged. A future option to expand the small-parts warehouse by an additional 2 aisles has already been taken into account.
Data and facts:
- 4-aisle, double-deep automated small-parts warehouse with order consolidation buffer for container base areas of 600x400 mm and 800x600 mm
- 18,240 container storage locations (600x 400 mm)
- Pre-zone platform
- 4 order picking stations for multi-order picking