• 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:
  • 17,772 pallet storage locations - 6 automatic pallet storage and retrieval cranes (30 double-cycles per AS/RS)
  • Pallet conveyors in the warehouse pre-zone with two high-performance crossways transfer cars Racking
  • Manual storage-system with 35,000 cardboard box storage locations
  • 2,300 m tote conveyors with 32 order picking stations


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.

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

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 Automobile Krafträder Fahrzeugteile

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 Werkzeuge AG (Switzerland)

The Requirements
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. 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 offering around 40,000 article storage locations
  • Drawer system: 260 cabinets with 2,340 drawers offering storage capacity for 52,543 storage locations for the small and smallest parts product line
  • Container conveyor technology: 1,230 m of conveying line
  • Order picking using pick-by-voice technology: Shelf storage system, drawer system, pallet warehouse
  • Order consolidation buffer: 1 storage/retrieval crane, 504 container storage locations
  • Material flow computer and control engineering by Klinkhammer

Perschmann / Hoffmann Group, Tool Trading

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.

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 hourand 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.



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.   PDF reference sheet

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)
  • Different order types can be processed in parallel

Data and Facts

Container Conveyor technology:

  • Automatic l-point
  • 11 picking stations
  • 4 stations for incoming goods
  • 8 packing stations
  • 7 dispatch lanes
  • Storage for empty containers (container buffer)
  • Transport distance 900 m

Matrial flow control:

  • Interface with SAP Hostsystem
  • Order and priority control
  • Container split and printing of pick lists
  • Monitoring of preparation and dispatch area
  • Printers for tour labels, monitoring of container

Control technology:

Conveyor control system, visualization of conveyor technology

Winkler Logistik GmbH, Supplier for commercial vehicles parts

The Customer
Winkler is one of the leading European suppliers in the commercial vehicles parts sector. The core competences of the commercial vehicle specialist are an extensive full range of spare parts and a sophisticated logistics and delivery concept guaranteeing the fast delivery of spare parts.

The Requirements
The subsidiary, founded in 1987 as Rifag Logistics, ensures the provision of spare parts to Winkler customers all throughout Europe by having more than 100,000 spare parts for commercial vehicles in stock and by its fast delivery service.

The Solution
To be ready to meet future requirements while keeping a lid on personnel costs, the central warehouse in Ulm was expanded and redesigned. As general contractor, the Klinkhammer Group realized the complete logistics solution. The plant was designed as three-storied shelf storage and racked storage facility. By splitting the orders, the positions to be processed are distributed over several order picking stations. This way, the storekeeper is able to process a larger number of orders in less time. The order picking surface for the employee was scaled down to 400 square meters.  

Advantages for the Customer
Shorter ways to go and storing the most frequently used articles in the front sections of the racking makes it possible to pick between 500 and 600 positions a day - compared to formerly 250 positions maximum. Besides planning and assembly of the conveyor system, the scope of services provided by the Klinkhammer Group also included the control engineering and visualization part as well as the material flow control, the fire protection barriers and the integration of the automatic label printers and applicators.    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
  • PLC incl. system visualization

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 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