• Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

  • Klinkhammer Group Referenzen

References - Trade

Data and Facts

  • Silo-type warehouse with 17,772 pallet storage locations
  • 6 automatic pallet storage and retrieval cranes (30 double-cycles per AS/RS)
  • Pallet conveyors
  • Manual storage-system with 35,000 cardboard box storage locations
  • 2,300 m tote conveyors with 32 order picking stations

PUMA

The Customer
By creating a logistics center in Schlüsselfeld, the PUMA AG - one of the world’s leading manufacturers of sports equipment with headquarters in Herzogenaurach – merged their decentralized warehouses in one logistics center in Schlüsselfeld.

The Requirements
The aim was to store more than 35,000 articles of the PUMA product range in such a way to ensure error-free picking and shipping of products packed in cardboard boxes in very short time. Acting as general contractor, the Klinkhammer Group was in charge of the conceptual planning, complete supply of conveyors, control system and warehouse management software and turnkey delivery and handover of the project. The scope of services included also the complete building and construction work. For this project, decision was made in favor of a combination of automated high-bay warehouse and manually operated shelf storage system.

The Solution
Products are picked following the pick-pack principle using a simplified pick-to-light system. The automated pallet high-bay warehouse incorporates six aisles with around 18,000 storage locations. Stacker cranes for storage and retrieval and crossways transfer cars manage to handle 165 double operations per hour. Replenishment control to the shelf storage system (35,000 locations for cardboard boxes) on individual carton basis is also done in the pre-zone of the pallet high-bay warehouse. The customer cardboard boxes started at the i-point may be directed to up to 32 order picking stations. Once picking of the customer cardboard box has been completed, the latter first undergoes a random check and is then sealed and strapped automatically before it is transported to the shipping zone.

The Advantages for the Customer
In the logistics center, every 9 seconds (average calculated) a parcel leaves the plant; in total, around 35,000 different articles are logistically managed. Thanks to the operator guidance the error rate could be reduced down to the parts-per-thousand range at a daily volume of 40,000 parts being picked. Capacity limits, however, have not been reached yet – depending on the needs, expansion is possible in the high-bay warehouse, but also in the order picking area or of the conveyors.

Data and Facts

  • High-bay warehouse with 4,000 storage locations
  • Double-deep storage of pallets weighing up to 1.5 tons
  • Two destacker units

A.C.V.K., Wholesale - House and Construction

The Customer
A.C.V.K, headquartered in Kortrijk, Belgium, is actively doing business in the wholesale of materials for house and construction.

The Requirements
Given the production tolerances as to the coloring of tiles, a batch management was implemented which defines the nuances of the surface finish and quality and thus allows a consistent supply quality with regard to nuances of coloring. For the storage and handling of the A.C.V.K. products a high-bay warehouse with 4,000 storage locations was built and an existing manual warehouse integrated. One special feature of this solution is the double-deep storage of pallets weighing up to 1.5 tons.

The Solution
The receipt of goods is handled at a workstation that is equipped with two destacker units for carrier pallets of different formats. At this point, a decision is made whether the goods enter the automatic or manual storage area. Order picking in the high-bay warehouse is done at three picking stations consisting of three conveyors each for partial retrievals and two additional lanes for the retrieval of full pallets according to the goods-to-man principle. A carriage transports the goods to and away from the workstations depending on the order picking sequence. This is vital as the products to be handled are heavy and fragile. Already during the order picking process the products are pre-sorted on shipping pallets for the end customer  

The manual warehouse is operated via radio data transmission using forklift truck terminals. Order picking takes place according to the man-to-goods principle. The order initialization for combined orders from the high-bay warehouse and the manual warehouse section occurs in the automated warehouse section to flexibly complete the pre-configured order pallets in the manual warehouse area.  The workplace and web applications are multilingual. The customer may adapt translations himself.

Data and Facts

  • Container/bin storage , on 3 levels, 12.960 storage locations,
  • Block storage for pallets, 112 storage locations with forklift
  • DC21 Warehouse Management System
  • Pick-by-voice technology

AKF - Automobiles, Motorcycles, Vehicle Parts

The Customer
The article range of AKF focuses on spare parts for motorcycles manufactured by Simson and MZ.

The Requirements
The warehouse is split into a container/bin storage section, a manual high-bay pallet zone and a free warehouse area (block storage) for pallets. Marks on the floor divide the free storage space into several storage locations. This area serves as storage zone for slow moving articles with a low turnover.

The Solution
At first, the DC21 Warehouse Management System determines for an incoming order the storage locations for the goods to be picked.For goods in the shelf storage, an empty container is started via central order initialization at the container conveyor system (i-point). Then the container is routed successively to those zones (station picking) where goods have to be picked. Picking is done using pick-by-voice technology. The user, carrying a voice-MDE at the belt, reads the container barcode out loud and then receives via the headset the storage location coordinates for each product to be retrieved and the quantity to be picked.

Other stock movements (storage, relocation, replenishment, picking from other storage areas, stocktaking) are handled using conventional MDE technology with scanner and touchscreen which are also linked to the warehouse management system via radio data transmission.  To some extent, pallets in the high-bay racking can be accessed from the bin storage system (for retrieval). When picking small quantities of the pallets, this is also handled via pick-by-voice. The order splitting method finds the optimal solution between using up partial pallet quantities and the minimum number of accesses during order picking.

Depending on the settings made in the article master data, the warehouse management system generates replenishment transports from a simple pallet storage location to a pallet storage location accessible from the bin storage system. This way, goods from a simple pallet storage location are relocated to a storage location that is accessible from the bin storage system. Given that a retail shop is connected to the warehouse, there is also the possibility of carrying out an express order promptly and without using the conveyors – by manpower.

Data and Facts

  • Pallet storage system with a gallery level and standard storage system with narrow forklift truck (3,636 storage locations)
  • Modular shelving system: 13,000 shelves
  • Compact warehouse with 157,000 article storage locations
  • Tote conveyor system: 2,100 m
  • Order consolidation buffer: 2 storage/retrieval cranes, 2,700 container storage locations
  • Order picking using pick-by-voice technology: 160 picks/h/order picker
  • Pick-by-light technology: 240 picks/h/order picker
  • Warehouse management software DC21 with interface to the ERP-system

Brütsch Rüegger - Tools, Switzerland

The Customer
Product availability and delivery at high speed – these are the outstanding characteristics of the company Brütsch Rüegger Werkzeuge AG (Switzerland) offering a full range of quality tools in the areas of measuring, production and assembly technology as well as standard parts and occupational safety.

The Requirements
Customers ordering by phone before 17:00 CET or online before 17:30 CET will receive their goods the next morning.  To be able to keep this promise, an availability of 98.9% of all articles offered and the latest intralogistics technology are indispensable.

The Solution
Given the structural restrictions of the already existing building, we planned and realized with our customer a completely new building that consists of 2 halls with a total floor space of 21,160 m2 and incorporates customized automation technology. During the construction, commissioning and system implementation phase, negative effects on the daily business were not allowed to occur. This was especially of importance all the more as the Klinkhammer Warehouse Management System DC 21 was linked to an already existing ERP-system while in operation.

The Advantages for the Customer
An enormous increase in the picking performance as well as an increased delivery capability and quality demonstrate the perfect project planning and system implementation done by the Klinkhammer Group at the company Brütsch Rüegger Werkzeuge AG. Another benefit – increased safety and transparency in the process-controlled sequences and procedures. The continuous overview of all logistics movements allows Brütsch Rüegger to flexibly adapt to the daily business and to deploy employees dynamically and purposefully.

Data and Facts

  • Modular shelving system: 2 levels with 12,448 shelves (40,000 articles)
  • Drawer system: 260 cabinets with 2,340 drawers for 52,543 storage locations (small parts)
  • 1,230 m Container conveyor technology
  • Ppick-by-voice technology: Shelf storage, drawers, pallet warehouse
  • Order consolidation buffer with 1 storage/retrieval crane (504 containers)

Perschmann / Hoffmann Group - Tools

The Customer
Since 1996, the company Hch. Perschmann GmbH is a partner of the Hoffmann Group, Europe's leading system partner for quality tools. 2,700 employees, of which 432 are working with the companies Hch. Perschmann GmbH, Perschmann Calibration GmbH and Perschmann Poland, ensure nationwide coverage and support. The sales region of Perschmann covers the area situated along the virtual line between Kassel, Hannover, Lüneburg and Wismar from South to North and Kassel, Halle and Cottbus from West to East. The subsidiary Perschmann Sp. z o.o, headquartered in Poznan, is in charge of the entire Polish territory.

The Requirements
Over the past few years, the volume of articles almost doubled from 40,000 to nearly 70,000 articles. In order to be able to meet the promised delivery reliability of 99.9% and supply availability of 99% also in the future, it was necessary to adapt the number of storage locations available. Additionally, the aim was to increase the storage capacity particularly for small and smallest parts and to optimize the picking performance.

The Solution
In the new logistics building, the areas of goods receipt, storage, picking, packing and shipment of tools were completely reorganized. With an overall height of the new building of 10.70 m and a surface area of around 62 x 31 m featuring two floors, among others, a drawer system was established and connected by means of conveyors. During this process, the container conveyor technology of the existing building #2 was linked with the small parts drawer system and with the empty container buffer in the new building #3. Additionally, an extreme consolidation of small and smallest parts was achieved with short distances to go for picking. Thanks to the use of pick-by-voice technology it was possible to increase productivity, reduce error rates and further improve the picking performance.

The Advantages for the Customer
Given the high article storage density in the drawer system the walking distances for the order pickers at Perschmann have become considerably shorter. The working heights were ergonomically optimized as well. Beyond that, the order picking staff is guided via pick-by-voice technology which increases the picking performance from 90 picks to almost 150 picks per hour and picker. The error rate has decreased as well. Thus, by building a new logistics warehouse Perschmann has not only gained more space for quality tools and accessories, by implementing the intralogistics concept the company has also topped the promised performance in terms of supply availability and delivery reliability even with increasing product variety. Reference Sheet (PDF)

 

 

Data and Facts

  • Shelf storage system with 30,000 storage locations
  • Manual pallet storage section with around 1,000 locations
  • More than 500m roller conveyors connect 9 picking zones and stations
  • Pick-by-voice supported order picking
  • 400 picks/h; 450 pos/h; 100 packages/h
  • Paperless order picking
  • Warehouse management software DC21, interface to ERP-system

Riegler, Pneumatic Fittings

The customer
Originally founded as a small company in the Swabian town of Metzingen, Riegler has become meanwhile one of the largest and best-known suppliers of pneumatic fittings on the German-speaking market. For more than 40years now Riegler has served its customers as an innovative partner for "Pneumatics, ideas and more". On a warehouse surface of around 6,500 m2 the product range comprises around 10,000 reference catalogue articles (more than 20,000 single parts) supplied to round about 13,000 customers worldwide. With 17 representations in Germany and abroad, proximity to customers is not just a slogan, but a mission of Riegler. "Ordered today, supplied the next morning - even for large quantities", this promise is one of the fundamentals for the success of the company located in Bad Urach.

The challenge
Both the existing storage capacities and the existing logistic solution were no longer able to cope with the continuously increasing challenges of an efficient warehouse logistic. Given the fact that a major part of the orders (about 70%) is received at Riegler between 2 and 4 p.m., but needs to be supplied to the customer the next morning, a quick and reliable functioning of the conveyors is a MUST. With the new building offering considerably more space for the incoming goods and shipment department the warehouse logistics could be placed on a "new footing".

The solution
A highly-dynamic container conveyor system now connects all shelf storage systems on both levels. The warehouse was split into nine order picking zones. Product replenishment into the shelf storage system is accomplished by means of RF-terminals where products are supplied from the newly erected manual pallet warehouse. To be able to handle even smallest parts the system was completed by installing a multi-shuttle compact storage system; two already existing paternoster units were integrated. The customer order is started at the i-point by ordering a container from the empty container storage section. The containers then continue their way on the conveyors to one or several picking zone stations. Here, the picker is given the instructions via pick-by-voice, fills in the goods and confirms the picking process/order after having cross-checked the container's content. The container is then directed to further picking zones or directly to the packing department. Up to this point in time, order picking has been a completely paperless process - delivery note and invoice are printed out at the packing station only. Prior to packing an electronic weight check is performed to be able to correct possible picking errors by comparing the actual weight to the nominal weight. Prerequisite for this order processing strategy: The warehouse management was taken out of the existing warehouse management system and is now controlled by the DC21 warehouse management system of the Klinkhammer Group.  

The advantages for the customer

  • Increase of the picking performance by at least 30%
  • Considerable reduction of the order throughput times
  • Pick-by-voice, cross check and weight check minimize errors
  • Optimization of the storage strategy of A-, B- and C-articles by self-learning software (short ways)
  • Higher flexibility with order peaks (dynamic distribution of staff)
Klinkhammer Intralogistics

Data and Facts

  • 4.3 km container conveyor technology connect all storage areas
  • 28 order picking stations
  • 8 incoming goods work stations
  • Order consolidation buffer with multi-level shuttle (1,100 container storage areas)
  • 18 lift storage areas with 9 order picking stations and automatic replenishment buffer
  • Packing area with 20 packing stations
  • Material flow control: interface to SAP R2

Winkler Logistik - Supplier for commercial vehicles parts

The customer
Winkler is one of the leading European suppliers in thecommercial vehicles parts sector. The core competencescomprise an extensive full range of spare parts, asophisticated logistics and delivery concept guaranteeing the fast delivery of spare parts as well as competent advice by 250 professional specialist advisers. The subsidiary Winkler Logistik in Ulm ensures the supply of spare parts to the European customers of Winkler by stocking more than 100,000 spare parts for commercial vehicles and by its fast delivery service.

The requirements
In order to offer an even faster service, the existing plant not only had to be extended but entirely redesigned.

The solution
On the second level of the existing warehouse, 9 stations for small parts and pallet order picking were put into operation. Thus, the incoming goods and shipping areas could be separated locally. A special circulating lifter connects the different levels, distributes the containers from the incoming goods area to the intended warehouse levels and the containers with completed orders from orderpicking to the shipping area. A second i-point was integrated on the first level to split urgent orders and thus process them quickly and reliably. Thereby, the throughput time was reduced by a good 25 %. In the course of several extensions, additional halls were expanded. By connecting the pallet order picking warehouse to the container conveyor technology, an integrated automatic transport system between the existing logistics system and the redesigned incoming goods and shipping areas could be realized. A 3-aisle automatic order consolidation buffer with a high-performance multi-levelshuttle system supplies the packing area and 10 goods-out conveyor lines via container conveyor technology. 9 order picking stations are available for small parts in 18 lift storage areas. An automatic replenishment buffer ensures the supply of the lift storage areas.

The advantages for the customer

  • Increase of container throughput from 400 to 2,000containers per hour
  • Separation of material flows (replenishment andorder picking)
  • Increase of throughput speed by 50 % thanks to thecirculating lifter solution of Klinkhammer (creation ofbypasses)
  • Splitting of orders and faster processing due to asecond i-point
  • Direct feed-out of shop ware in close proximity tothe pick-up station
  • Shortened processing times

Reference Sheet (Pdf)

Data and Facts

  • 500 m of conveyors
  • Automatic order consolidation buffer
  • Shelf storage (21,000 containers)
  • Pallet storage system (4,000 pallets)
  • 330 long goods in the cantilever warehouse
  • 6 incoming goods stations
  • Warehouse Management Software and material flow computer

Frankana - Camping and Leisure Market

The Customer
Together with the sister company Freiko, Frankana belongs to the leading wholesalers in the camping and leisure equipment business. The product range of Frankana comprises more than 10,000 different articles. It incorporates batteries, gas cartridges and folding spades as well as awnings for caravans, camping toilets, tents and floor coverings.

The Requirements
A great challenge at Frankana is not only the high variety of products regarding shape, material and size and allocation to different storage areas resulting thereof, but also the consolidation of the goods from the different areas.

The Solution
Following the successful realization and commissioning of the 1st expansion stage, Klinkhammer was also contracted for the 2nd expansion stage by Frankana. The expansion provides an optimization of the processes by means of connecting intelligently the storage areas using conveyors. Previously mainly represented by forklift trucks, the six new incoming goods work stations, the modular shelving systems with totes, the automatic order consolidation buffer and the shipping department of the 2nd expansion stage are connected by means of conveyors. This is ensured by creating a conveyor technology connection across 3 floors. The further optimization of the material flow and a higher throughput of goods was the aim of the automation. The Klinkhammer warehouse management software, the material flow computer and the order picking via pick-by-voice are expanded as well. Each conveyor section in the order picking area features buffer positions in incoming and outgoing direction to guarantee working without interruption at the order picking stations.

The Advantages for the customer
Modern conveyor technology is connecting the six new incoming goods work stations, the modular shelving systems with totes, the automatic order consolidation buffer and the shipping and guarantees the high product availability and delivery reliability. PDF Reference Sheet

Data and Facts

  • Silo-type high-bay warehouse (2,276 pallet locations; around 72 x 25 x 16m / L x H x W)
  • 2 stacker cranes
  • 1 crossways transfer car and various conveyors
  • 1 labelling- and scanner station
  • Materials flow- and warehouse management computer

JELD-WEN - Timber Industry

The Customer
Jeld-Wen in Öttingen is one of the worldwide leading manufacturers of doors. A series production with maximum degree of automation by production lines requires flexibility, fast response and accuracy in intralogistics.

The Requirements
For the storage of door blanks Klinkhammer realized a new, silo-type high-bay warehouse featuring two aisles. Thanks to combined telescopic forks being used as load handling device, special automated storage and retrieval cranes can move complete stacks of doors.  A telescopic fork being arranged on top (including gripper) allows picking single doors (also in pairs). A positive side effect of the gripper is securing the load when transporting a stack on the load handling device.  Door stacks are always located on so-called protection boards to prevent the products from being damaged. The warehouse pre-zone is used for handling door stacks during storage and retrieval.

The Solution
With each process, the door(s) pass along a fully-automatic scanning and labeling unit which reads the door labels and applies new labels, if required. This way, incoming stacks are received and outgoing stacks are labeled for the next production step. In the warehouse, the automated storage and retrieval cranes can consolidate, restack, sort out or cover door stacks. In DC21, each door is registered and managed with a unique product identification. Product properties (dimensions, weight, date of manufacture, batch) and the exact position in a stack are saved for future access.

The Advantages for the customer
The automated storage and retrieval cranes with special load handling device for the automated picking (INTEGER) of doors create a production-suitable product stack which then run to the machines. The load handling devices with gripper picks up the doors by clamping them. During this phase, the material flow computer transmits the door properties, the quantity picked and the stack height to the automated storage and retrieval crane such that the latter is able to position perfectly and control the speed during picking and placing.The formation of stacks occurs based on the production sequence (predefined by the Manufacturing Execution System), height and weight specifications and taking into account order changes. Thus an order picking sequence is established.  PDF reference sheet

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