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f+h Intralogistics 2/2016

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f+h Intralogistics 2/2016

Consumer goods

Consumer goods manufacturer relies on Jungheinrich WMS DS Produkte, a consumer goods manufacturer, has complex requirements for its warehouse management system. By employing Jungheinrich WMS, the company benefits not only from the system’s optimized, transparent and secure processes in all intralogistics areas, but also from enhanced productivity and greater adaptability to changing circumstances. Our tour of the logistics center located in Gallin in the north-east of Germany is essentially an excursion through the facility’s omnipresent warehouse management system. In the words of “tour guide” Frank Müller, Head of Logistics Operations at DS Produkte: “As a result of expanded customer and order structures as well as our company’s growing sales, it became indispensable to invest in a WMS system that would seamlessly reflect our intralogistics processes. The previous warehouse management system from a different provider was no longer up-to-the-minute, since it only allowed us to manage high-rack warehouse inventories.” Complex requirements SOFTWARE MULTIMEDIA CONTENT Learn more about the achievement spectrum of the enterprise DS Produkte originally ordered the WMS in a “light” version that included the most important standards. Twelve months after initial implementation, the other functions were added. The standard version of Jungheinrich WMS already includes extensive functions for warehouse modelling, equipment control and optimization of material flows as well as centralized master data administration. The standard version also offers a comprehensive reporting function that provides individually configurable analyses and as a result complete process transparency. In addition it features numerous standard interfaces which allow the user to hook the WMS system up to existing system environments, plus a number of different inventory options. Müller begins the tour in the WMS work preparation area, where staff members follow each process on their screens while issuing and managing orders. “We were looking for a WMS provider who was capable of meeting our highly complex customer and item-specific requirements,” says Müller. This complexity is due on the one hand to the many intralogistics areas which are connected with the logistic center’s WMS system (Image 01). This includes incoming goods, which takes in a daily total of 500 pallets’ worth of items, along with a 13 m high narrow aisle warehouse consisting of 32 aisles, each of them 37 m long, and 17,000 pallet storage slots as well as cantilever shelves installed at the front of the high-rack warehouse and which are used as transfer stations. Added to this are the packing and loading areas, a wide aisle order picking warehouse and the outgoing goods area where a total of approximately 500 pallets and 5,500 packed packages are handled daily. Apart from the 30,000 pallet storage slots inside the f+h Intralogistics 2/2016

01 Staff members in the WMS work preparation area track all processes on their screens, while issuing and managing orders 02 One solution consists of the packing areas, for which the manufacturer adapted and expanded the WMS packing functions logistics center, the WMS also manages 5,000 additional slots in outdoor storage. The high degree of complexity is also due to the operator’s broad range of tasks, for which special solutions were required. One solutions highlight consists of the packing areas where the WMS – equipped with adapted and expanded packing functions – receives customer-specific packing instructions and has the orders processed accordingly (Image 02). To demonstrate the diversity of these tasks Müller enters the B2C packing area. “This is where delivery slips, invoices and return labels are printed out and placed, often with flyers, in the packages along with the goods.” Comprehensive processing of returned orders DS Produkte moreover uses the WMS to control a bypass function at the narrow aisle warehouse, plus the one and two-stage order picking at the logistics center as well as returns processing which includes the reception, processing and return to stock of saleable goods. Apart from this Jungheinrich put the focus on accelerated processes. One example consists of order picking using finger scanners which enable staff members to hold a package with two hands and at the same time scan its barcode. A second example involves the cantilever racking, where the WMS interacts with RFID transponders to ensure 100 % accuracy, including both the transfer of the goods delivered by reach truck as well as their pickup via narrow aisle forklifts controlled by the warehouse navigation system. The use of the WMS system in combination with RFID transponders results in time savings of approximately 20 % in order processing. And the WMS also provides for easier and more efficient inventory management as well as substantially more reproducible and executable processes and a high degree of adaptability to new requirements. Among the most important Jungheinrich WMS modules employed by DS Produkte are the Client Module, Material Flow Computer, Production Order Module and BBD Management Module as well as the custom-developed Returns Module. A stacker control system operating via wireless communication was moreover implemented, one that guarantees a balanced utilization of the capacity of the Jungheinrich-delivered fleet of trucks, consisting of four narrow aisle stackers, eight reach trucks, nine tri-lateral forklifts, five sprinters and nine low platform side-seat trucks. Close cooperation A close cooperation has existed between DS Produkte and Jungheinrich since 1995, when the Stapelfeld-based consumer goods manufacturer began planning its logistics center in Gallin. DS Produkte placed a premium on a high degree of flexibility and performance capability, making the decision to invest in industrial trucks, rack systems and planning support from Jungheinrich. As Müller recalls, “Jungheinrich scored points primarily because it was a complete systems provider. What really convinced us was the coherent systems advice and practical experience they had accumulated by implementing a number of similar projects. We were also pleased that our requests in terms of system security and occupational health and safety were taken seriously.” Müller sounds equally satisfied with his company’s choice of a WMS system, reporting that Jungheinrich had “fully met” his company’s complex requirements: “The solution consisted of controlling the processes based on the order category. We see the results in optimized, for instance faster processes, a high degree of transparency in terms of the data and goods in all warehouse areas, a tangibly lower error rate and higher productivity. The latter allows us to process a substantially larger number of orders without needing to hire more personnel or spend more time.” DS Produkte also gives high scores that that package consisting of software, warehouse technology and industrial trucks all come from a single supplier, thus making any discussion of interface problems superfluous. The company also emphasizes the fine quality of service for all these areas, including useful advice and support in commissioning the various systems and the high availability of the WMS, which is in operation six days a week and up to now has never had a breakdown. Both companies are continuing their cooperation in joint workshops as a basis for possible necessary adaptations of the warehouse management system to changing circumstances. According to Müller: “New computer and WMS-relevant tasks have arisen, owing to the fact that our original planning assumed around 4,000 orders per day, but now we have up to 11,000. This jump in orders is due to an increase in B2C orders.” As the growth of DS Produkte appears to presage additional developments of this kind, the company can only benefit from the “future-proof” nature of Jungheinrich WMS. Photographs: Jungheinrich 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. f+h Intralogistics 2/2016


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