Professional Documents
Culture Documents
Company magazine
Cover story Automotive
Food industry
Brose Group:
4
Innovative tugger train solution
eliminates need for forklifts
Vinamilk:
17
Vietnams high-tech dairy
distribution centre
Khne + Nagel:
Innovative combination
of systems
www.ssi-schaefer.com
18
Editorial
Dear readers,
We are committed to helping our customers maintain
their competitive edge in the global marketplace. Increasing throughput, streamlining material flows and
ensuring reliable processes while reducing error rates
to almost zero these are just a few of the objectives
companies across multiple industries approach us
with. To help them achieve their goals, we implement
both manual warehousing systems and fully automated, turnkey distribution centres.
Intralogistics has developed into a high-tech industry,
with automated warehouse and logistics processes,
and purpose-designed software. The technologies we
deploy in our projects reflect this trend: they include
high-throughput warehouses and storage systems, efficient picking solutions, fully automated storage and retrieval machines, sophisticated robotics, intelligent inventory data capture methods, and reliable warehouse
management software. Our automotive-themed cover
story on the Brose Group spotlights many of these solutions in action.
Harrie Swinkels
Managing Director, SSI Schaefer, Giebelstadt, Germany
Contents
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18
4
12
20
Automotive
8
Manufacturing
Project Liebherr-Aerospace/Lely/
Glenbeigh/Belimo Americas/
Klingspor/Schunk
12
Retail
Food industry
20
Special feature
22
Project LANDI/NBTY
14
18
Automotive
Efficient pallet
live storage
Manufacturing
Taking efficiency
to a new level
Within the scope of a large-scale
expansion of their production plant,
Liebherr-Aerospace Lindenberg has
built a new logistics centre. All
processes in this automated highefficiency warehouse are managed
with WAMAS software.
The three-aisle
high-rise racking
was installed on
a floor that had
been lowered by
20 metres.
Eco-friendly intralogistics
for Lelys new campus
Maassluis, the Netherlands. The Lely Group is an
acknowledged pioneer in the agricultural sector.
Its portfolio includes forage harvest machines,
automatic livestock feeding systems, mobile barn
cleaners, and robotic milking systems.
SSI Schaefer installed in-line shelving at 18 assembly stations on the high-tech production lines
at Lelys new innovation campus. This shelving
ensures that small parts are always easily accessible, and precisely where they need to be.
SSI Schaefer also provided a pallet racking system for Lelys warehouse, for storing materials
sold by the metre.
In the future, Lely will also deploy SSI Schaefer
LTB containers to reduce waste packaging generated during production, and to minimise the companys environmental footprint.
of a significant number of cartons. The intralogistics expert implemented a multi-tier mezzanine system; the racks make full use of available
headroom, and can store one million cartons. By
leveraging vertical storage, SSI Schaefer eliminated the need for an increased footprint, and
doubled the warehouses capacity.
The multi-tier
mezzanine system
can store up to one
million cartons.
Manufacturing
Made-to-measure
warehouse solution
for Belimo Americas
Accelerated picking improves
material flows and increases
throughput.
Connecticut, USA. SSI Schaefer has implemented a 7,000-square-metre automated warehouse for Belimo Americas, a manufacturer of
actuators and control valves.
The scope of services included automated small
parts storage with 16,320 tray and container
positions, container conveyor systems, a pallet
live storage system, narrow-aisle pallet racking,
SSI Schaefers WAMAS logistics software, and
goods-to-person workstations for picking, packing, and pre-assembly.
The conveyor system loop serves three picking
zones, including the narrow-aisle racking, the live
storage system, and the picking workstations,
where extremely fast-moving AA, fast-moving A,
and slow-moving B SKUs are stored, respectively. The goods are retrieved by Schaefer Miniload
Design of Klingspors
pallet racking and
shuttle-served channel
storage systems.
At the production plant in Haiger, SSI Schaefer is installing a threeaisle, double-deep pallet racking system, with 13,400 positions, and a
shuttle-served channel storage system with 36,000 container positions. The new configuration will incorporate SSI Schaefers innovative 3D-MATRIX Solution which
provides outstanding efficiency, flexibility, redundancy and scalability.
Three energy-efficient Exyz storage and retrieval systems will streamline putaway and picking in the 2 x
120-channel pallet racking system. A pallet conveyor system with a programmable logic controller (PLC)
connects the 26-metre-high racking system to three picking stations and the receiving and shipping
areas. On the other side of the building, a Navette shuttle system comprising 21 Navette vehicles and
nine Navette lifts serves a 26-metre high channel storage system. This storage system is linked by
conveyors to four staging areas located in the extremely high-turnover AA SKU zone, and to four multiorder stations and eight packing stations. In addition, Klingspor plans to introduce SAP EMW (Extended
Warehouse Management) software, which will also be implemented by SSI Schaefer. The upgraded
warehouse is slated to commence operation in mid-2016 and will play a key role in the enterprises
future growth.
10
Manufacturing
an integrated receiving area and only speciallytrained warehouse staff may enter. Their task is to
handle more complex requests from electricians,
to pick and put away components, and to plan
inventory (including placing orders for corresponding products). SSI Schaefer equipped the parts
issuing desk with drawer shelving.
11
Retail
12
Retail
13
Food industry
Kllby, Sweden. Swedish family-owned company Dafgrd has been developing and supplying
high-quality ready meals since the 1930s. Today,
Dafgrd is Swedens preferred brand of readymade meals, producing 40 million Billys pizzas
every year and 400,000 meatballs every hour.
Space-saving seafood
storage
Tuticorin, India. Nila Sea Foods specialises in
seafood products, and offers a range of over
45 SKUs, including lobster, cephalopod, crab, fish
and shrimp.
Until recently, Nila Sea Foods stored its frozen
products in its own cold storage warehouse,
and at facilities operated by third-party logistics
Nila Sea Foods uses a mobile
providers. However, limited storage space made
racking system to store its frozen
seafood products.
it difficult to directly access all SKUs. Nila Sea
Foods mission is to supply its high-quality goods
on time, to ensure end-to-end product traceability,
and to safeguard the cold chain at all times. For this reason, SSI Schaefer was tasked with upgrading
the existing warehouse. A key role is played by a mobile racking system with a total of 1,830 pallet
positions. This has enabled more efficient use of available space.
The automatic racking system helps us to increase our productivity and reduce product damage.
Moreover, it consumes less electricity, takes up less space, and includes more safety measures.
This allows us to easily handle and trace products, explains Mr Chandran, General Manager of Nila
Sea Foods.
14
Food industry
15
The SRMs are equipped with shuttles as loadhandling devices, enabling three- to four-deep
storage in the rack channels. The HBWs design,
with a channel storage system, improves storage
flexibility and throughput of newly introduced products, explains Ingvar Lge, manager of the new
At the core of SSI Schaefers logistics solution is a warehouse in Jren. A 400-metre long pallet contemperature-controlled high-bay warehouse (HBW), veyor system connects the HBW with the producwith close to 7,200 pallet positions. Due to the tion and shipping areas.
sensitive nature of its goods, the cooling system is
equipped with an oxygen-reduction fire prevention SSI Schaefers WAMAS logistics software mansystem. Putaway and picking tasks are performed ages and monitors warehouse processes. The
by four storage and retrieval machines (SRMs), cold chain is maintained through a combination
with a throughput of 33 pallets per hour. The of automation, software, and storage and picking
SRMs and their components are ideal for oper- systems. Furthermore, WAMAS helps streamline
ation in temperature-controlled warehouses, the entire supply chain, from farm to supermarket
states Peter Lambrecht, Head of Project Manage- freezer.
ment at SSI Schaefer.
A conveyor system
moves cartons from
the packaging zone
to the buffer area.
However, Italpastas continuous growth created real challenges for its packaging department. Space constraints in production, and poorly structured
warehouse processes posed a risk to employee and food safety.
For this reason, Italpasta tasked SSI Schaefer with automating and restructuring the corresponding processes without disrupting ongoing operations. SSI Schaefers solution was
to construct a bridge, with two integrated conveyors, to connect the manufacturing plant to the adjacent building used to hold finished goods. The conveyors move cartons from 21 packaging lines to the
buffer area, where they are sorted and stacked before being sent to one of four automated palletising
stations. Here, they are palletised, shrink-wrapped, labelled, and prepared for shipping.
The solution has enhanced efficiency, improved staff working conditions, and increased space available for equipment now, there is nothing standing in the way of Italpastas progress.
16
Food industry
Eight energy-efficient
Exyz SRMs perform
pallet putaway and
retrieval.
17
Innovative combination
of systems
Khne + Nagel, the global logistics player, tasked SSI Schaefer with creating a
highly flexible and efficient distribution centre for its business operations in the
Netherlands. The result is a 12-aisle high-bay warehouse for foodstuffs, with
an integrated Orbiter shuttle system, an electrified rail-guided vehicle (RGV)
system and conveyors with a total length of around one kilometre. The facility
also features layer-picking robots with innovative grippers.
Utrecht, the Netherlands. Worldwide, Khne + Nagel
offers its customers approximately seven million
square metres of storage space including more
than 33,000 square metres in Utrecht, the Netherlands. SSI Schaefer, Giebelstadt, Germany, was
contracted to create a logistics centre for storing
foodstuffs for multiple customers. The result is a
facility that combines a variety of highly advanced
technologies.
18
19
Special feature
SS
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Giebelstadt, Germany. Warehouses play a significant role in any logistics infrastructure. However, the
components deployed in these facilities are, over a
typical period of seven to 15 years, overtaken by
technological advances, rendering them obsolete.
They are often no longer able to effectively support
the latest business processes and growth strategies. The consequences are high operating costs,
inflexibility, and reduced competitiveness.
Po
e
nc
Made-to-measure customer
service and support
ive
Insp
ent ance
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P in
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20
Special feature
cards in the holders. During the shift, the warehouse management system (WMS) transmits the
picking and transfer jobs directly to the onboard
terminals. Both the completion of pallets for putaway and the transfer of pallets to conveyors are
reported to the WMS via RFID, and coordinated
via the material flow control system. The new
Three industrial UHF RFID read/write devices RFID technology delivers huge time savings and
were installed at the Balingen distribution centre creates seamless putaway processes.
to detect the picking trucks and forklifts at the
three pallet receiving stations. In addition, each Thanks to this powerful technology and high-peremployee was given a personal identification card formance components, data collection is reliable
with an RFID chip, and all trucks used for pallet and error-free, reports Patrick Zurheide, who
receipt were fitted with special card holders.
manages Kempfs distribution centre in Balingen.
Thorough preparation enabled SSI Schaefer to
At the start of each shift, employees log on to complete the conversion in just one week
the terminals on their trucks, and place their RFID without disrupting ongoing operations.
The challenge was to enhance existing installations while the logistics centre continued to operate at full capacity, reports Robert Ranftl, who
managed the project for SSI Schaefer. To avoid
disruptions in the shipping department, work was
mainly carried out at night.
Greater capacity has produced positive results:
Oriflame can now ship products promptly and reliably, even during peak periods. The entire project
was conducted to the highest professional standards. It was the best weve ever been involved
in by far, says Lukasz Kielczewski, Operations
Manager at Oriflames logistics service provider,
Logwin Air + Ocean, Poland.
21
Growing demand
for upgrades
Klaus Reichert, Head of Fulfilment,
Customer Service and Support at
SSI Schaefer, Germany.
22
++++++++++++++
Production plant
expansion in Asia
The Navette is equipped with two load-handling devices, one positioned above the
other. This enables the system to put away and retrieve items simultaneously
performing two actions in just one cycle.
Simpang
Reng gam,
Malaysia.
SSI Schaefers expanded steel production plant went into operation in February 2014. A new rolling mill, the same
type used by the parent company in
Germany, will soon process all profiles
for high-bay racking systems which
may be up to 40 metres in height. Additionally, systems for preparing special
steelwork profiles will be installed.
23
About update
Published by (responsible for content): SSI SCHFER / FRITZ SCHFER GMBH Fritz-Schfer-Strasse 20 57290 Neunkirchen/Germany
Public Relations / editorial team: Angelina Kuhn email angelina.kuhn@ssi-schaefer.com
www.ssi-schaefer.com
SSI SCHAEFER SYSTEMS INT. INC.
P. O. Box 7009 10021 Westlake Drive USA-Charlotte, N.C. 28241 Phone +1/704/9444500 email general@ssimail.net
update en/us 0344-042015-w 2/042015 Printed in Germany by Griebsch & Rochol SSISCHFER Products featured in articles may be subject to change and technical modification. Errors and omissions excepted.