LOGISTICS content, the WCS distributes the incoming totes to one of three induction areas,” explains Lückmann. The conveying technology transports them to the workplaces where the items are taken out of the totes. Each item is identified with a matrix camera and placed on the sorter. Empty totes are returned to the conveying system and follow the track back to the receiving area. “We provided our Beumer BS7 Belt Tray Sorter for this sorting process,” explains Lückmann. This system manages a throughput of around 14,000 without presorting, and up to 27,500 items per hour when using the described presorting process. Destinations ensure gentle sortation Power and data transmission on the Beumer BS7 is contactless. This prevents mechanical friction losses and wear and tear. Compared to conventional cross-belt sorters, this sorter has 50 percent less components, which reduces maintenance costs by 80 percent. Energy requirements are also reduced during production and operation. The distance between the individual conveying elements on the Beumer Group systems is reduced to a minimum. The use of belt trays makes it possible to have narrower, more closely arranged destinations. Therefore, the sorter requires less square footage. “The special feature of our BS7 are the 361 specially developed destinations, that ensure careful handling of the very different spare parts,” so Lückmann. Everything must be sorted and discharged while keeping the packaging intact. To this end the destinations are divided in two parts. If the spare part weighs up to 1.4 kg, the WCS classifies it as “light”, up to six kilogram as “heavy”. This way the heavier parts are placed in the tote or cardboard box before the lighter parts when the order is picked. “The XL items from the main storage are handled differently,” explains Lückmann. “Their size means that only one spare part fits in one tote or box.” They are picked separately and conveyed directly to the consolidation area. The same happens with items from other buildings like tyres and hazardous material. Together with the items from the packing sorter, the orders are consolidated in totes and boxes and put together into shipping units. The units are then weighed, compared with the target weight, closed, labelled and then strapped. They are conveyed to the connected shipping sorter that distributes the consolidated orders to up to 50 different dispatch destinations, at a capacity of 2,500 totes per hour. And what if the spare parts are not working or are no longer needed by the customer? “They go back to the logistics centre in Zakroczym,” explains Lückmann. Employees examine the returns: is the part damaged, was it just not needed or was it the wrong choice? If it is still in its original condition, it goes back to the warehouse. The material flow for all these processes throughout the entire distribution centre is controlled by the WCS, from inbound to outbound. The orders are sent from the operator’s warehouse management system.
02 The totes are placed on the roller conveyor and transported automatically to the packing sorter 03 The Beumer BS7 Belt Tray Sorter manages a throughput of around 14,000 without presorting, and up to 27,500 items per hour when using the described presorting process 01 Beumer Group installed the entire conveying, picking and sortation technology for car parts dealer Inter Cars S. A. at its new European Logistics Centre Residential service: Beumer Group takes responsibility Beumer Group continues supporting the project even after this point. ILS opted for the residential service, a special component of the Beumer’s comprehensive customer support, to focus more on the their own core business. “With this 24/7 service, the Beumer employees ensure availability of the machines and systems,” reports Jaroslaw Gorczynski, General Technical Director, Poland. “It must be perfectly coordinated during the entire operating time, so that all processes run smoothly.” The team has its own control room, and the workplaces were designed in a way so that potentially critical areas can be reached as quickly as possible. The Beumer Group employees also perform preventive maintenance work. Gorczynski explains: “This way, we can avoid unplanned machine breakdowns that can get very expensive for the customer.” The team carries out maintenance and inspection work on the systems at defined intervals. They also check the safety devices, electrical components and automation technology. And they can perform repairs that might be necessary in case of an unscheduled failure of components. The team checks the technical installations and maintains them regularly, at agreed intervals. The contract with Beumer Group runs over five years until 2022. Guaranteed system flexibility “Our systems and machines fully met the customer’s targets. The system offers high level of availability, high and precise throughput and can be easily adjusted to changing customer requirements. The same holds true for our modular WCS,” describes Lückmann. The owner is very happy with the cooperation: “We were able to accommodate all requirements. Delivery, installation and commissioning went all according to plan.” The companies are currently in talks about an extension of the system. Photographs: Beumer Group www.beumergroup.com WORLD OF INDUSTRIES 1/2019 27