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f+h Intralogistics 2/2015

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f+h Intralogistics 2/2015

INTRALOGISTICS ICR

INTRALOGISTICS ICR relies on Jungheinrich intralogistics When ICR, the Italian perfume manufacturer from Milan set out to bring its intralogistics up to the state of the art, it was also a decision with ramifications for the future. ICR found a partner for the job of jointly developing a suitable concept with intralogistics specialist Jungheinrich. In this manner a special system solution was developed featuring industrial trucks equipped with RFID technology and oriented towards the strategic market goals of ICR. Milan, the capital city of fashion, is also an important center for the perfume industry. Headquarters of the company, which has specialized in producing aromatic fragrances for more than 40 years, are in Lodi, not far from metropolitan Milan. A passion for making perfume The success story of today’s company, ICR Industrie Cosmetiche Riunite SpA, began under Vincenzo Martone, founder of the company, who started producing pharmaceutical products in 1940. The know-how obtained in this manner determined the future business development of the company and led to an expansion of the product range with skin care products. In 1975 Roberto Martone, the founder’s son, began specializing in the production of perfume. Led today by Roberto Martone and his daughters Ambra and Giorgia Martone, ICR has now become a leading producer of premium Italian perfumes for Italian fashion designers. World-famous brands originating with ICR include names like Asprey, 24 f+h Intralogistics 2/2015

INTRALOGISTICS Blumarine, Bulgari, Custo Barcelona, Dsquared2, Salvatore Ferragamo, Gianfranco Ferré, Pomellato, Trussardi, Emanuel Ungaro. ICR is responsible for all activities for these brands, from developing the fragrance (together with the respective brand providers) through production at the highest industrial standards and on to worldwide sales based on efficiently operating intralogistics. More than three million liters of perfume for numerous fashion designers are produced annually in the large modern ICR plant in Lodi. The production facilities have a capacity of 27,000 liters per shift and up to 250,000 bottles of perfume can be packaged in the same time. Bottled in containers for the respective brands, about 85,000,000 flacons and bottles are processed a year, packaged and sent all around the world, (117 countries to be precise) in the form of 100,000 orders. To manage these large quantities (as well as numerous components from atomizer pump to cap coming from the warehouse some 70 kilometers away in Cortemaggiore) in the company’s internal logistics system, and provide the basis for reliable delivery service, ICR relies on an efficiently operating intralogistics system optimally connecting production, warehousing and shipping. Searching for a partner to help with planning, conception and implementation of the project, the ICR opted for industrial truck manufacturer and intralogistics specialist Jungheinrich. The company has been active in the Italian market for years, has extensive know-how and adequate experience in projects implemented in Italy, and was already known to Francesco Gullo (Image 01, right), Director of Planning and Logistics Projecting at ICR, from projects in sectors other than perfume manufacturing. The initial situation Before ICR began considering how to redesign their intralogistics, they were using numerous industrial trucks from another manufacturer, which were responsible for all transport tasks, stacking and retrieving pallets and providing support for picking, etc. But Gullo wanted more. His goal was to create a logistics solution that would make ICR capable of achieving greater productivity and efficiency along the entire intralogistics process from the end of production, through incoming goods, storage and picking, including integration of industrial trucks equipped with RFID technology with tasks assigned to them, and on to preparation for shipping. Another indispensable requirement was being able to trace shipments of goods seamlessly. Gullo: “What matter most to us was for logistics to make a noticeable contribution towards improving delivery capability and service, in turn contributing significantly to more customer satisfaction and thus supporting the company goal of greater growth.” For Thomas Viola (Image 01, left), head of logistics systems, Jungheinrich subsidiary in Rosate, the most important thing was “for ICR to achieve the goals it had set with the logistics solution implemented by us and industrial trucks equipped with RFID technology.” Concept and structure of the new intralogistics It quickly became clear that the requirements and goals could not be reached with the logistics structure and technology available at that time. After analyses carried out together with the logistics institutes of Italian universities, ICR came to the conclusion that the best way to achieve the goals they 01 Pleased with the results of the warehousing reorganization: ICR Logistics Director Francesco Gullo (right) and Thomas Viola, head of logistics systems, Jungheinrich subsidiary in Rosate About Jungheinrich Jungheinrich is one of the world’s leading companies in the industrial truck, warehousing and material flow engineering sectors. As a manufacturing service and solution provider in the field of intralogistics, the company, based in Hamburg, Germany, supports its customers with a comprehensive product range that includes forklift trucks, shelving systems, services and consulting. The Jungheinrich share is traded on all German stock exchanges. had set was to reorganize logistics and use modern industrial trucks and an innovative, forward-looking technology such as RFID. As the perfume manufacturer searched for a provider with the required expertise in both areas, industrial trucks and logistics systems, attention focused on Jungheinrich in Rosate, not even 30 kilometers from the plant in Lodi. Aside from the company’s experience in planning and implementing logistics systems and integrating industrial trucks, Jungheinrich’s immediate proximity to the ICR production site in Lodi was very helpful for the overall flow of the project. And so together with ICR, Jungheinrich developed the concept as follows: Coming out of production, picked perfume bottles and flacons fully packaged in cartons are stacked on pallets. An employee places labels on the foil pallet packaging with a barcode label and RFID data carrier (tag). Then the cartons are made available via an EFG electric forklift truck for loading onto a shuttle vehicle. The vehicles that move the pallets the short distance across the plant grounds to the finished goods warehouse are loaded by ERE series electric pedestrian-controlled pallet trucks. At the beginning of the loading process, the scanner installed between the forks of the industrial truck reads the barcode label. At the moment the pallet is picked up, the RFID reader compares the TAG code with the recorded barcode. If the two match, that information is transferred to the warehouse management system. To ensure that all pallets and especially the right pallets are loaded, an RFID gate is installed on the back of the loading opening of the shuttle vehicle which can be used for comparisons. After a short transport route from production to finished goods warehousing, which consists of a high-bay and a narrow aisle area, the shuttle vehicles are loaded and unloaded there with series ERE pedestrian-controlled pallet trucks with stand-on f+h Intralogistics 2/2015 25

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