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f+h Intralogistics 1/2016

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f+h Intralogistics 1/2016

SSI Schaefer storage

SSI Schaefer storage system ensures just-in-sequence-production WAREHOUSING At the Porsche production plant in Leipzig three different models run the assembly lines at the same time. In order to install the correct wheel to each car model, an automated tray storage system ensures the process reliability and just-in-sequence availability of complete wheels. I n 2014, 66,005 units of the Porsche Cayenne, 59,363 of the Macan, and 22,383 of the Panamera rolled off the assembly line at the carmaker’s plant in Leipzig. The final step in the manufacturing process is to fit each vehicle with a set of wheels. And that is where the service provider Deutsche Hendricks Logistik/Germany plays a key role. The enterprise assembles wheels at its nearby logistics centre, inflates the tyres, and tests the completed units before delivering them just-in-sequence (JIS) to Porsche. To ensure seamless JIS supply, Deutsche Hendricks Logistik opted for an automated tray storage system – and chose to partner with SSI Schaefer. Due to a rising volume a further aisle was added to the racking in 2015. Now there is a total storage capacity of 2,230 tray positions. f+h Intralogistics 1/2016

Supply capacity expanded Leipzig was not traditionally known for automotive engineering. However, for Porsche, it has become a home from home. Final assembly of the Porsche Cayenne began in 1999. The luxury SUV has proven extremely popular, and operations in Leipzig have continued to expand ever since. In 2009, the carmaker added production of the Panamera, its four-door sedan. In 2014, the marque commenced manufacture of its Macan compact crossover, including fabrication and painting of bodies. Deutsche Hendricks Logistik’s own Leipzig success story began in summer 2012, when the enterprise won a competitive RFP to supply fully assembled wheels and tyres – to be delivered just in sequence (JIS) to Porsche’s production line. To make this possible, the service provider constructed its 16,000 m² facility at a freight transportation hub located just three kilometres from the carmaker´s plant. The building was completed in just six months, and features manual storage for wheels and tyres – plus an automated system for assembling and testing the complete wheels. These are then transferred to an automated staging area, and subsequently conveyed to a robot that loads them onto JIS-compatible racks. MULTIMEDIA CONTENT Learn more about the achievement spectrum of the enterprise. A complex challenge SSI Schaefer worked hand-in-hand with Deutsche Hendricks Logistik to design and implement the three-aisle tray storage system for the JIS supply of the wheels. The two organisations had built a working relationship through previous RFPs. In addition, the service provider already uses SSI Schaefer racking systems. When selecting the ideal combination of solutions for the Porsche RFP in spring 2012, the partners placed particular emphasis on process reliability and availability. Minimising downtime was imperative; if the wheels do not arrive right on time at Porsche’s plant, the cars are held up on the production line – and all upstream activities grind to a halt. A further challenge is the concurrent assembly of all three Porsche models at the Leipzig plant, making JIS delivery even more complex. Bernd Frankemölle, Head of Project Implementation, Automated End-to-End Systems, SSI Schaefer, explains: “The complete wheels must be delivered in sequence for three-shift production. With this in mind, Deutsche Hendricks Logistik opted for an automated system. Moreover, redundant access in two aisles to central tray positions maximises availability.” The highly compact, three-aisle tray storage system (Image 01) is of single-deep configuration, and has a total of 2,230 tray positions. The 1,800 × 900 mm trays, capable of supporting loads of up to 200 kg, each hold two stacks of two wheels – a complete set for each car (Image 02). The trays were designed and manufactured specifically for Porsche in Leipzig. A robot places the assembled wheels onto the trays, prior to them being moved to transfer stations at the end of each aisle (Image 03). The wheels must be loaded onto the trays in the correct order (front/back, left/right). If an issue is detected during testing and a wheel has to be reworked, the three others are held back, and stacked in a rack. Wheels are put away and picked in a single action. Trays retrieved from storage are placed on conveyors, transferred, and loaded by robot onto JIS-compatible racks for Porsche in Leipzig, or racks for other customers. Additionally, business continuity procedures are in place, should the automated conveyor system suffer an outage. In these scenarios, the storage and retrieval machines (SRMs) can be used to manually retrieve wheels, and ensure their timely delivery. Karl-Andreas Moll, Director, Automotive Group at Deutsche Hendricks Logistik, underlines the solution’s benefits: “We followed SSI Schaefer’s recommendation to construct two aisles. This means we can still retrieve wheels when maintenance work is being performed on one SMC – we can continue to use the other storage and retrieval machine to access centrally located tray positions. For this 01 Each storage and retrieval machine is fitted with special grippers to handle the trays 02 The wheels are automatically loaded and stored. Each tray holds two stacks of two wheels – a complete set for each car reason, the wheels to be supplied next are staged in this section, to ensure timely delivery. In addition, process automation ensures that only the trays requested by the SAP system are retrieved.” In 2015 Deutsche Hendricks Logistik and SSI Schaefer added a third storage aisle. This not only increased capacity and streamlined retrieval tasks, but also doubled the number of the centrally located high-availability tray positions. Automation also prevents damage to the wheels, and minimises physical strain on employees. Furthermore, it eliminates errors when loading wheels onto the JIScompatible racks; a final barcode scan verifies that the right wheel is in the right position on the rack. f+h Intralogistics 1/2016

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