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World of Industries 3/2020

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World of Industries 3/2020

With good planning and

With good planning and teamwork for a successful retrofit LOGISTICS Many components were discontinued. This was a challenge for the smooth operation of Metabo’s 24-year-old production warehouse in Nürtingen (Southern Germany). With a detailed system analysis, the viastore retrofit experts identified all critical elements and created a binding roadmap for the measures required. Thus, with good advanced planning, Metabo was able to manage the three-week modernization phase without any supply bottlenecks and ensure long-term availability of the warehouse. 1995: The year in which Austria, Sweden and Finland joined the EU, leading electronics manufacturers agreed on a common standard for DVDs, and Christo wrapped the Reichstag in Berlin. And in which Metabo, a traditional manufacturer of power tools for professional users, is increasing its turnover to almost half a billion Deutschmarks. At that time, the company based in Nürtingen (near Stuttgart) had viastore Systems, the Stuttgart-based international supplier of intralogistics systems, build a new automated warehouse to provide supplies to production in order to create capacity for further growth. After 24 years a risk for availability With success: Today Metabo scratches the 500 million turnover mark – and the warehouse still supplies production safely with components and raw materials. However, after 24 years, reliability was no longer entirely adequate, as Dennis Bosch, Head of Logistics at the main plant, explains: “Although we had modernized the material flow computer back in 2005, the number of failures increased over the years, even if it was not proliferating.” Metabo wanted to avoid the risk of a shutdown, because the warehouse must always be available – production at the tool manufacturer is structured in such a way that replenishment must be available at the production site after a maximum of four hours. “viastore has regularly reminded us that obsolete components pose a risk to availability in our plant,” says Bosch. System analysis as the basis Finally, in 2018, the decision was made to increase the availability and reliability of the warehouse, and secure it for the next few years. “For this, viastore extensively analyzed the condition of the entire system”, says Dennis Bosch. Lars Breuer, Assistant Director Retrofit at viastore, explains: “Because logistics systems are becoming increasingly complex, an analysis is extremely important.” The retrofit experts examine the condition of each component and each module of the warehouse system. Such a system analysis can take up to three weeks – but the effort is well worth it. As a result, the operating 6 WORLD OF INDUSTRIES 2020

01 Many components had already been discontinued in the 24-year-old Metabo production warehouse company receives a graphical overview, which evaluates each component in terms of its modernization needs and displays it in the form of a traffic light: If the traffic light is “green”, there is no need for action, “yellow” issues should be kept in mind, and “red” requires the fastest possible measures. “With this analysis, we work out the risks very clearly and can derive corresponding actions. In addition, we develop proposals for reorganization, as our customers’ processes often change over the years,” explains Breuer. All traffic lights on red “There was hardly a traffic light on green”, Dennis Bosch remembers. Lars Breuer goes into detail: “Many components were discontinued. Spare parts were no longer available for the old S5 controls in the conveyor system and the automated storage and retrieval systems.” Above all, the IT hardware was outdated. It relied on the old Sinec L2 FMS bus system for communication with the conveyor system, for which the interface cards were no longer available. “It was the cyber attack of 2017 that opened our eyes permanently,” recalls Dennis Bosch. At that time, the virus Petya infected more than 1,000 workstation computers and 350 servers at Metabo and caused an interruption of production and supply lasting several days. All affected systems had to be completely rebuilt – the discontinued interface cards could only be organized with difficulty somewhere else. “That made it clear once again what availability means,” says Bosch. 02 After a comprehensive analysis of the plant, Metabo decided for a holistic retrofit Exact planning based on a detailed roadmap Based on the system analysis, the company decided not only to modernize individual components, but to carry out a comprehensive retrofit. “The necessary preparatory work was quite extensive,” recalls Dennis Bosch. “We had to remove material from the warehouse that was needed in production during the period of modernization, and put them in other places in the factory – in a specially built tent and also directly in the various departments.” To allow Metabo to schedule of all this, viastore defined a time frame that the Ethernet cable Ethernet cable Tested for 15 million double strokes Tested for 15 million double Test strokes 4888 Test 4888 Record torsion for cables with ± 360 °/m Record torsion for cables with ± 360 °/m ● Robot cables directly from stock ● Sold by the metre or harnessed ● From 1 m, with no cutting charge and ready-to-connect ● Robot cables directly from stock ● Sold by the metre or harnessed ● Tested in the largest laboratory ● Online service life calculation ● From 1 m, with no cutting charge and ready-to-connect in the industry ● 36 month guarantee ● Tested in the largest laboratory ● Online service life calculation motion plastics ® ... for in longer the industry life ● 36 month guarantee Tel. +49-2203-9649-800 info@igus.eu motion plastics ® ... for longer life Tel. +49-2203-9649-800 info@igus.eu .eu/chainflex .eu/chainflex EU-1245N-CFROBOT8+ 185x130.indd 1 20.04.20 11:26 EU-1245N-CFROBOT8+ 185x130.indd 1 20.04.20 11:26 WORLD OF INDUSTRIES 2020 7

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