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f+h Intralogistics 1/2015

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f+h Intralogistics 1/2015

WAREHOUSING The modular

WAREHOUSING The modular warehouse management system from Hörmann Logistik permits effective processes Depending on the branch, tasks of the company and objective, intralogistics are demanded in a multifaceted manner. Examples from the industry have shown how the respective tasks can be solved conceptually and technically. The role of a warehouse management system that can be applied flexibly in the process is clear when an individual management of the flow of goods is required in the individual functional areas. Kern & Sohn GmbH, weighing technology suppliers, was able to present continuous growth of the company over the past years. Intralogistics could not keep pace with this commercial success. In order to optimize the material flow, the Protema Unternehmensberatung GmbH consultants therefore developed an overall concept that, next to a new logistics and assembly concept, also included the new construction of a plant and logistics building. The backbone of the new processes is an automatic palette high bay warehouse and an automated small parts warehouse. For the implementation including the linked picking locations, Hörmann Logistik GmbH from Munich, Germany was awarded the prime contractor contract. A decisive factor that Hörmann Logistik was awarded the contract was the concept developed for the automated small parts warehouse where cardboard boxes and small load carries of different sizes could be stored. The automated small parts warehouse is integrated in the silo of the 25 m high palette high bay warehouse. Thus, the small parts warehouse also has a height of 25 m. This height could only be implemented by the use of a special construction for the racking storage and retrieval vehicles – a solution where only one traction drive drives the running gear as well as the mast head via a gear rack. Using a special grasping technology, the cardboard boxes in different sizes can be stored up to a fourfold depth. Several width classes of the load carriers permit a volume optimized assignment of the rack shelves. At the goods receipt, the palettes and cardboard boxes are identified using barcode readers from the warehouse management system Hi LIS from Hörmann Logistik, the weight as well as contour are checked and the cardboard boxes are assigned into width classes. Via continuous handling equipment, the palettes reach the pre-zone of the palette high bay warehouse. The racking storage and retrieval vehicles pick up the palette and store them at the location 34 f+h Intralogistics 1/2015

WAREHOUSING defined by the management software. Depending on the size of the cardboard boxes and the optimum rack shelf allocation, the software determines if the cardboard boxes should be rotated on the transport route to the automated small parts warehouse. Hi LIS obtains the orders from the host computer for the retrieval. By passing on the retrieval orders at an early stage, the warehouse management system can couple orders of the same width class and thus, using the racking storage and retrieval vehicles, can collect up to four cardboard boxes in the automated small parts warehouse and make them at the retrieval table. Moreover, it is possible to sort the cardboard boxes to the picking before supplying to the “Pick & Pack” places if sequence requirements are at hand for the respective order. Hi LIS also requests the palettes in the palette high bay warehouse and are supplied to the “Pick & Pack” places using the conveyor technology. The fact that the same warehouse management software can be used in different trades is shown in the example for corrugated board processing. Here the operator profits from, e.g. the real time visualization that the system offers. Green Bay Packaging Inc. has specialized in the manufacturing of corrugated board packaging, folding cardboard boxes as well as self-adhesive labels. In the course of expanding the plant in Wisconsin, a new high-bay warehouse with material handling systems is being built that will be linked directly to the existing production area as well as to the coating and cutting units, which are also new. The packaging manufacturer has also commissioned Hörmann Logistik as prime contractor for the design of the high-bay warehouse, including the linking conveyor technology. Paper rolls as well as different palette types can be stored in the fully automated two aisle channel storage system. In doing so, two racking storage and retrieval vehicles are operating on one rail in one aisle of the high-bay warehouse and one storage and retrieval vehicle in the other aisle. The racking storage and retrieval vehicles are each equipped with two channel vehicles Each truck is equipped with an RFID-Gate in order to clearly document the loaded palettes that can be run separately (for smaller palettes) or together (with system palettes for rolls). In order to ensure the redundant supply with raw goods, the middle rack unit can be operated from both aisles. In the goods receipt, the paper rolls are unloaded from the truck and placed on the system palette using a line portal. According to a barcode and contour control, the raw goods are passed on to the storage tables of the high-bay warehouse. If the production requires raw goods, the warehouse management software Hi LIS selects the respective roll that the racking storage and retrieval vehicles can retrieve the quickest. This prevents stock transfers. The roll retrieved is forwarded to another portal using the conveyor technology and there, is taken direct to the production plant using an automated guided vehicle. Returning the finished coated rolls back to the warehousing is carried out in the reverse order using the same technique. In order to optimize the material flow, Hi LIS instructs the material handling system to store the raw material in different areas of the high-bay warehouse according to the plant to be supplied. Using this strategy avoids having two racking storage and retrieval vehicles obstructing one-another in the same aisle when optimizing the route times in the process. Permanent transparency and quick error diagnostics are ensured in event of malfunction using the real time visualization of the warehouse management system. Flexible storage of packaging made from corrugated board At the company headquarters of the corrugated board manufacturer Soenen Golfkarton in Hooglede, Belgium, , a manual block warehouse was, until now, operated for storing the finished goods. The growth over the past years, however has resulted in the company needing a new reorientation of their storage strategy. Hörmann Logistik processed a detailed intralogistics concept with a fully automated high-bay warehouse as a primary component of their plan. Corrugated board formats, finished corrugated board packagings and empty palettes are stored in the new high-bay warehouse. The dimensions of the palettes vary between 1,200 × 800 and 1,800 × 2,350 mm, with maximum heights of 2,200 mm. Linking to the production is carried out using two conveyor routes on which the palettes are centered, checked for contours and read per RFID-Tag. Then the acceptable palettes run through a sorting area. Large format palettes are passed through this area, smaller formats that make up approx. 90 percent of the overall production are grouped into pairs. A roller conveyor brings the palettes to the transfer area of an electrified monorail with which the load carriers are transported to one of the six storage spaces of the highbay warehouse. In doing so, each hanger can pick up two palettes at the same time. The handling of the load carriers in the high-bay warehouse is taken over by racking storage and retrieval vehicles equipped with telescopic forks. Each storage and retrieval vehicle can transport maximum two pairs (four palettes) at the same time. The Hi-LIS Power management system belongs to the equipment of the six racking storage and retrieval vehicles that allows them to save up to 25 percent energy. For shipping, the goods requested by the tour order via Hi LIS are retrieved by the racking storage and retrieval vehicles, where possible also in pairs again and are taken to the truck loading zone via the conveying route as well as the electrified monorail. Each of the loading zones, eight in total, are equipped with four conveyor belts in order to allow the goods out to be completed quickly. In the production, the palette and the corresponding production order are “married” with Hi LIS. The tracking of the palettes per RFID technology takes place consequently up until the palettes are loaded onto the truck. Each hall door in the loading area is equipped an RFID-Gate (image). This allows the loading of the palettes to be clearly documented and avoids incorrect loading. Construction of the high-bay warehouse started in Fall 2012 and commissioning took place in February 2014. Photos: Hörmann Logistik www.hoermann-logistik.de About Hörmann Hörmann Logistik GmbH with its headquarters in Munich, Germany, is part of Hörmann Holding GmbH & Co. KG, which is split into two business branches – industry and communication. The company implements intralogistic systems for different sectors with the help of warehousing and conveyor technology concepts and logistic warehousing technology. The manufacturer assumes full responsibility for the implementation of complex new warehousing systems, as well as the modernization of existing systems during continuous operation. Hörmann Logistik operates internationally, is represented in thirteen countries, and currently employs around 4000 staff around the world. f+h Intralogistics 1/2015 35

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