• Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

References - Production

Data and Facts

Capacity

  • Silo-type warehouse - 5,676 pallet storage locations
  • A-warehouse: 82 order picking lanes
  • B/C-warehouse: 5,135 pallet storage locations
  • HF-warehouse: 4,340 pallet storage locations

Devices

  • Fully-automated storage and retrieval crane with double "Muli" satellite vehicles, reach truck, palletizing robot, automatic pallet stretch wrappers

Performance

  • Production: ~ 500 cardboard boxes/h
  • Palletizing: 30-50 pallets/h
  • B/C-warehouse: 30 pallets/h
  • Storage/retrieval A-warehouse: 40 pallets/h
  • Order picking: 3,000 positions/day

BIG-Spielwarenfabrik GmbH & Co. KG

The Customer
BIG-Toys, a company of the Simba-Dickie Group, produces toys in its factory in Burghaslach and ships them to wholesalers and retailers all over the world.

The Requirements
The Klinkhammer Group was responsible for planning and realizing the complete intralogistics. The flow of goods comprises the various production and assembly areas – from blow forming and injection molding, to supplying the assembly lines with all necessary components from the semi-finished goods store, to storing the finished products in the high-bay warehouse – as well as retrieval and picking of customer orders.

The Solution
Thanks to the use of radio frequency for data transmission all material flow transactions are linked. The heart of the solution is an around 30 meters high silo-type warehouse featuring a capacity of 5,700 pallet storage locations and fully automated “satellite vehicle” stacker crane used for crosswise storage (multiple load handling device, ten pallets deep storage) which ensures storage and retrieval of finished goods and the supply of goods to 90 order picking lanes. At these picking lanes, individual cartons are picked. Another 9,500 pallet storage locations are available in two manual pallet racking systems where pallets are stored and retrieved by means of high reach trucks. Via the SAP-interface, master data, storage data and order data are received. Same applies to production orders which contain bills of material and are prepared for delivery to production. For this, a production module was integrated in DC21.

Via conveyors, the production delivers the goods directly to a palletizing robot. Following the automatic load securing, the goods reach the shipping center. Picking orders are broken down to packaging units (order splitting). Hence, a position may consist of pallets, individual cartons and individual pieces and then be processed in an order-related manner or in parallel in several zones. A spacious consolidation zone in the shipping area is used for merging the goods that belong to one order. 

Data and Facts

  • Pallet high-bay warehouse: 22,884 storage locations
  • Automatic small-parts store: 15,360 containers à 600 x 400 mm

Conveyors:

  • Pallet conveyors: 7 pallet stacker cranes with double load handling device, around 300 m of conveyors (incl. 2 lifts, 1 crossways transfer car)
  • Tote conveyors: 3 tote stacker cranes, around 1000m of conveyors

Software

  • Material flow control (MFC) / warehouse management system (WMS)

Performance data:

  • 12 power order picking stations: 150 pos./h, 500 full cardboard boxes/h
  • 6 small-parts picking stations: 120 pos./h, 450 wallpaper rolls/h
  • 1 returned goods workstation
  • Shipping area: 20 full pallets/h and 620 individual cardboard boxes/h

Marburger Tapetenfabrik J. B. Schaefer GmbH & Co. KG

The Customer
Marburg wallcoverings is a highly performing, mid-sized company. Wallpapers manufactured by Marburg wallcoverings reach customers in more than 80 countries all over the world. The full-line supplier offers quality wallpapers for all requirements, luxury wall coverings for an exclusive atmosphere, design objects made by artists like Ulf Moritz, Luigi Colani or Karim Rashid and technical wall coverings for industrial buildings and hotels.

The Requirements
The product range of Marburg wallcoverings comprises more than 4,000 different wall coverings. While formerly large quantities were ordered and stored by the retailers in their stores, nowadays highly flexible and customized orders are in demand. The logistic concept used so far was not able to cope with the trend toward smaller order quantities and shorter cycles.

The Solution
The responsible managers at Marburg wallcoverings opted for a fully-automated solution for both the high-bay warehouse and the small parts storage section. 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 homogeneously and stored in the warehouse fully automatically.

The dual load handling devices with parallel replenishment unit guarantees maximum efficiency. When distributing the goods over the warehouse, criteria such as sales frequency or production sequence play a vital role. This data is stored in the program of the Klinkhammer warehouse management system. The logistics center at the front of the newly built high-bay warehouse is the key element of this logistic solution. 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 on all levels is no problem. Once delivery is ready for shipment, conveyors ensure transporting the orders to the labelling station and finally to the dispatch area. The labelling system has been certified for all large shipping companies such as Deutsche Post or UPS. Small orders, supplier samples, brochures or promotional products are retrieved from the adjacent automatic small-parts warehouse – featuring 15,360 tote storage locations – and then directed to the “picking workplaces for small quantities”. At these workstations products are repacked and automatically transported on to the next station. Deliveries containing complete orders are conveyed automatically to the i-point where they are transported by forklift trucks to the shipping zone.

Advantages for the Customer
The fully automated solution in all zones of the warehouse increases transparency of the goods movements in the warehouse, minimizes throughput times and cuts down the time from receiving the order to goods shipment. The warehouse management software of Klinkhammer thereby provides a permanent and continuous overview of all logistic flows and access on all levels.   Reference Sheet

Klinkhammer Group

Data and Facts

  • Automatic pallet high-bay warehouse, 1,708 storage locations
  • Automated small parts warehouse, 8,316 tote storage locations
  • Warehouse management system integrates automatic warehouse zones, lift storage areas, a manual high-bay warehouse, three block storages, a manual racking system, a cantilever storage, a cable storage and a crossdocking block storage
  • 8 assembly line storage areas and 15 pre-assembly workplaces are linked to the warehouse management software via stacker control system

Göpfert

The Customer
Göpfert is one of the leading machine manufacturers worldwide for processing corrugated cardboard. From its company headquarters in Wiesentheid, Göpfert manages and controls all steps from development, production, assembly through to global sales.

The Requirements
More than 300,000 parts, ranging from smallest screws to large drive shafts, are held available in different warehouse types. In order to expand production and sales, the principle of manual warehousing needed to be fundamentally reconsidered, as this principle repeatedly reached its limits. When expanding the location with new intralogistics, the focus was on higher safety, transparency and speed.

The Solution
The company's growth and the desire for digital networking made a rethink necessary in intralogistics. The manual processes for the assembly line and spare parts supply were replaced by an automated, compact warehouse and paperless order picking. The lean automation solution combines a tote and pallet warehouse including pre-zone and order picking workstations thus ensuring a smooth and optimized

flow of materials. The warehouse management software KlinkWARE® integrates 8 assembly line storages, 15 pre-assembly workplaces and all storage areas from tote storage, cantilever and block storage through to the lift and pallet storage. In addition, the new goods receiving area with incoming goods inspection for external suppliers' products as well as the shipping area for new and spare parts have been seamlessly integrated and linked.

Advantages for the Customer
High and continuous transparency, speedy processes in the goods receiving and shipping area, minimization of the error rate. Thanks to the intelligent material flow concept, the networked software and the new automation solution, Göpfert today is one step ahead of its competitors also in terms of intralogistics.   

Reference Sheet

Data and Facts

  • Tray warehouse (automatic small parts warehouse), 1595 trays with 1230 x 820 mm
  • Up to 16 types of containers of different sizes per tray
  • Manual pallet warehouse (1,000 storage locations) with narrow forklift trucks and radio data transmission
  • Retrofit of system control (retrieval crane and conveyors)

Gerhard Mosca AG

The Customer
The company Mosca located in Waldbrunn is one of the leading manufacturers of strapping systems.

The Requirements
A tray warehouse (automatic small parts warehouse) was erected in the existing, very low storage rooms. Up to 16 types of containers of different sizes (for small parts; grid-type load handling device) can be stored on one tray. This allows greatest possible flexibility as to the efficient use of storage space.

The Solution
A manual pallet warehouse with around 1,000 storage locations was created for the storage and handling of bulky goods. The receipt of goods for the automatic small parts warehouse occurs in the pre-zone of the warehouse, at a work station with integrated scales. Narrow forklift trucks and radio data transmission guarantee the handling of goods in the pallet warehouse. The article master data define whether the goods enter the automatic small parts warehouse or the manual pallet warehouse. The manual warehouse is operated via radio data transmission using forklift truck terminals and MDE. Order picking takes place according to the man-to-goods principle. Order picking in the automatic small parts warehouse is done at 3 picking stations.

Advantages for the Customer
A carriage transports the goods to and away from the picking stations depending on the order type. This is important as orders are divided into order groups which are processed by specialized staff members. After picking has been completed, a consolidation takes place with the goods coming from the manual area. Additionally, the automatic small parts warehouse is linked to a KANBAN system which was implemented to automate the supply of consumables to production.

Data and Facts

  • 13.5 m - 16.5 m high pallet high bay warehouse composed of seven aisles with 7 storage and retrieval cranes and 9,000 pallet storage locations, optimized and adjusted to the roof pitch
  • 10 picking work stations for pallets
  • 1 automated container storage system, 7,440 storage locations

Software

  • Klinkhammer Visualization system
  • Klinkhammer Warehouse Management Software DC21 and materialflow computer

Schletter, Metal Industry

The Customer
The family-run company Schletter, founded in 1983, is one of the leading manufacturers of innovative light metal products and European market and technology leader for intelligent solar assembly systems. Individual solutions made of aluminium profiles from the own press shop, powder coating for series production or the complete product development including design, engineering, packaging and logistics are provided directly by the plant in Kirchdorf/Haag, located in Upper Bavaria. There are 20 subsidiaries throughout the world. Additionally, products are manufactured in the factories in the USA, South Africa and China.

The Requirements
For the company Schletter GmbH - actively doing business around the globe - the objective consisted in replacing the manually operated warehouse by a fully-automated pallet high bay warehouse to considerably increase the goods-in and goods-out capacity. Beyond that, the goal was also to restructure the flow of material and to optimize the picking process in order to guarantee fast supply availability even at a high volume of orders.

The Solution
A 16.5 m high pallet high bay warehouse composed of 7 aisles and featuring 7 storage and retrieval cranes as well as 10 power picking stations for pallets is in the centre of the warehouse with a footprint of around 9,500 m2. The storage capacity totals to 9,000 pallet storage locations. Additionally, a single-aisle, automated container storage system was integrated which is connected to the goods receiving area and to other storage areas by means of conveyors. The different materials to be conveyed and loaded, ranging from euro-pallets and grid box pallets to containers, represented a major challenge. The control of conveyors and handling equipment is ensured by the material flow computer of Klinkhammer which transmits all relevant information about loading unit and transport order. 10 power picking stations and the "Goods-to-Man" principle made it possible to considerably increase the number of picks per staff member during order picking. Due to the high performance requirements, decision was made in favour of designing two conveyor roundabouts each with a capacity of 140 pallets/h. This way, the necessary supplies performance for the power picking stations is guaranteed. To cut down the change time to a minimum, two source pallets with direct access and two pallet locations for buffering are always available per each picking work station. Two target pallets are allocated to each work station. This allows multiple orders to be picked.

Advantages for the Customer
An automated system replaces the manual processes at Schletter to quickly and reliably control complex processes. Now a pallet high bay warehouse, an automated small-parts warehouse and optimized order picking strategies ensure smoothly running processes, a high supply availability and transparency of the goods in stock.

Reference Sheet

 

 

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