Kunert Wellpappe Bad Neustadt GmbH & Co.KG is part of the family-run Kunert Group. Today, the Kunert Group employs 1,900 people in 16 plants in Europe and Asia. Annually, the Kunert Group produces 300,000 tons of corrugated board cores, edge protectors and packaging, as well as over 225,000 tons of corrugated board cores. A new automated high-bay warehouse was built at the Bad Neustadt site to create space for production expansions and to meet changing customer requirements for smaller order quantities, shorter delivery cycles and efficient inventory management. With an innovative concept, HÖRMANN Logistik took over the realization of the new warehouse with connecting conveyor technology. Special feature of the four-aisle channel warehouse is the multiple-deep cross storage of a wide variety of finished goods formats on different types of pallets as well as on several sub-pallets.

Concept

The packing units are transported from production by a distribution trolley for transfer to the new conveyor system. Already in production, care is taken to ensure that, if possible, two identical packing units are always transported one behind the other, which can then be conveyed as pairs in the high-bay warehouse area and stored and retrieved. This significantly increases the throughput of the warehouse. A packing unit can have up to six sub-pallets. The packing units are centered and checked for length, width, height, pallet width, pallet length and weight via a contour control system.

The conveyor system then brings the packing units to the prezone of the high-bay warehouse, where a pallet circuit with special chain conveyors and roller lifting tables connects the production, high-bay warehouse and shipping preparation areas. For storage in the new channel warehouse, the packing units are precisely positioned at the storage spur with the aid of a light grid. The two-mast storage and retrieval machines (SRMs) are equipped with chain conveyors and channel trucks. In two aisles of the warehouse, the SRMs operate with one channel truck each, while in the other two aisles they operate with two channel trucks each to handle the transport of large pallets.

The channel trucks are battery-powered and are charged on the fly at the AS/RS. The stacker crane picks up the packing unit crosswise and stores it multiple depths in the storage channels with the help of the channel trucks. During order-related retrieval, the HiLIS warehouse management and control system receives a retrieval order via interface from the on-site HOST. The goods are retrieved by the stacker cranes and transported via conveyor technology towards the shipping area. There are different loading areas for truck rear loading and truck side loading.

BACK TO REFERENCES

In more than 20 years Imaging Development Systems GmbH has developed from a 2-man company to a worldwide leading manufacturer of digital industrial cameras with about 300 employees. Around 200,000 high-quality cameras "Made in Germany" are developed and manufactured in Obersulm every year. With subsidiaries in the USA, Japan and UK, as well as representative offices in Europe and Asia, IDS is internationally represented. At the headquarters in Obersulm, a fully automated small parts warehouse is being built in an existing warehouse, in which goods receipts or picking can be carried out at any workstation at any time. Hörmann Logistik has taken over the implementation of the innovative small parts warehouse AutoStore® as general contractor.

Concept

For the tailor-made design of the AutoStore® system, Hörmann Logistik carried out several system simulations with real data from IDS during the planning phase. The daily operating times of 10 hours, together with other customer requirements and the simulation results, led to a system configuration with approx. 2,610 containers measuring 649 mm x 449 mm x 220 mm (L x W x H) over 10 levels. The 5 autonomous robots supply and remove the three carousel workstations. One of them is assigned for goods receipt, one for goods issue to production and one for goods issue to shipping. The AutoStore® system consists of an aluminium grid system clad on three sides with overall dimensions of 10.6 m x 11.2 m x 2.4 m (L x W x H), excluding the service platform. In the grid system, stacks of 10 containers each are placed directly on the hall floor. Above the stacks of containers is the rail system (grid) on which the five battery-operated, autonomous robots move and cooperatively pick up and re-sort containers and deliver them to the order picking modules. The maximum total weight of the containers is 35 kg, with a net payload of around 30 kg. An overweight check is carried out at the ports in order to safeguard the maximum weight. The containers can be flexibly subdivided by separating inserts for the use of several articles.

The system is designed for 800 storage and retrieval operations per day. The system is controlled by the HiLIS AS warehouse management and control system, which was specially designed for AutoStore®. AutoStore® "only" knows the tote number in the system, but not the contents. The higher-level WMS HiLIS AS knows the content of each container, takes over the higher-level management and control of the AutoStore® system and implements the logistical processes including the interfaces to the ERP system. The comprehensible, graphical user interface of HiLIS AS provides clear work and picking instructions via touch screen. In addition, HiLIS AS supports permanent inventory processes, empty container insertion, status dialogues, special access to the containers and much more.

The AutoStore® small parts warehouse at IDS in Obersulm was put into operation in May 2019.

ZURÜCK ZU DEN REFERENZEN

An der Firmenzentrale in Passau wird zur Lagerung von Auto- und Motorrad-Zubehör bzw. Ersatzkleinteilen in einer bestehenden Lagerhalle ein vollautomatisches Kleinteilelager errichtet, in dem an jedem Arbeitsplatz jederzeit Wareneingänge oder Kommissionierungen durchgeführt werden können. Wegen seiner kompakten Abmessungen, der hohen Effizienz und der optimalen Ausrichtung auf den e-commerce hat sich die Auto Leebmann GmbH für das innovative Kleinteilelager AutoStore® entschieden. Den Auftrag zur Realisierung hat HÖRMANN Logistik als Generalunternehmer übernommen.

Konzept

Für die maßgeschneiderte Auslegung des AutoStore®-Systems wurden bei der Planung von Hörmann Logistik mehrere Anlagensimulationen mit realen Daten von Auto Leebmann durchgeführt. Die geforderten Betriebszeiten zur Wareneinlagerung (4 Stunden pro Tag) und Warenausgang (8 Stunden pro Tag) führte zusammen mit den weiteren Kundenanforderungen und den  Simulationsergebnissen  zu einer  Systemkonfiguration mit einer Gesamtkapazität für 10.750 Behältern, wobei das Grid zunächst nur mit ca. 6.000 Behältern der Größe 649 mm x 449 mm x 330 mm (L x B x H) befüllt wird. Die 15 autonomen Roboter mit 15 Roboter-Ladestationen ver- und entsorgen die vier Carousel-Arbeitsplätze. Zwei davon dienen zur Einlagerung, zwei zur Auslagerung und Kommissionierung der Artikel.

Zur späteren Erweiterung sind zwei zusätzliche Carousel-Rahmen vorgesehen. Das AutoStore®-System besteht aus einem an drei Seiten verkleideten Aluminium-Rastersystem in den Gesamtabmessungen von 14,1 m x 26,9 m x 4,4 m (L x B x H) inklusive der Service-Bühne. In dem Rastersystem stehen Stapel mit jeweils 13 Behältern direkt auf dem Hallenboden. Über den Behälterstapeln ist das Fahrschienensystem (Grid) montiert, auf dem sich die 15 batteriebetriebenen, autonomen Roboter bewegen und kooperativ Behälter aufnehmen, umsortieren und an die Kommissioniermodule andienen. Damit auch zukünftig der erforderliche Staplerverkehr in der Bestandshalle erfolgen kann, wurde im Grid ein Tunnel mit ausreichender Höhe vorgesehen. Das maximale Gesamtgewicht der Behälter beträgt 35 kg bei einer Netto-Zuladung von rund 30 kg. Zur Absicherung des Maximalgewichts findet an den Ports eine Übergewichtsprüfung statt. Das System ist für 1.100 Ein- und 3.000 Auslagerungen am Tag ausgelegt.

Die Steuerung der Anlage übernimmt das speziell für AutoStore® konzipierte Lagerverwaltungs- und –steuerungssystem HiLIS AS. AutoStore® kennt „nur“ die Behälternummer im System, nicht aber den Inhalt. Das übergeordnete LVS HiLIS AS kennt den Inhalt jedes Behälters, übernimmt die übergeordnete Verwaltung und Steuerung des AutoStore®-Systems und setzt die logistischen Prozesse inklusive der Schnittstellen zum ERP-System um. Die einfach verständliche, grafische Benutzeroberfläche von HiLIS AS stellt via Touch-Screen klare Arbeits- und Kommissionieranweisungen zur Verfügung. Zusätzlich unterstützt HiLIS AS permanente Inventurprozesse, Leerbehälter-Einbringung, Status-Dialoge, Sonderzugriff auf die Behälter und vieles mehr.

Das AutoStore® Kleinteilelager bei Auto Leebmann in Passau ging im Frühjahr 2020 in Betrieb.

ZURÜCK ZU DEN REFERENZEN

The Pati-Versand has specialised in patisserie supplies, confectionery and baking ingredients and accessories since 2007. The extensive product range, which is expanded annually with the latest trend articles, is also available in the tailor-made online shop. Today, www.pati-versand.de is the largest provider of cake, praline and baking ingredients for private customers in the German-speaking world. At the Herzlake location, an automated small parts warehouse for the storage of baking accessories is built in a new warehouse. Hörmann Logistik convinced with its AutoStore® concept and received the order to realise the system including the HiLIS AS warehouse management system.

Concept

The AutoStore® warehouse is built in the new building with a clearance height of 5,500 mm. Goods receipts and picking can be carried out at all workstations at any time.

For the individually tailored design of the AutoStore® system for Pati dispatch, Hörmann Logistik carried out several system simulations with original data in real time during the planning phase. The net operating time is 8 hours daily, 5 days a week.

The customer parameters together with the simulation results led to a system configuration with 12 levels, 25,000 containers, 6 carousel workstations and 2 conveyor workstation modules. This enables the required 110 goods storage and 1,040 goods retrieval operations, including the approximately 10 "fast orders" per hour, to be implemented. For a possible extension, 3 or 2 additional frames for carousel or conveyor workstations are already planned.

The AutoStore® system consists of an aluminium grid system with the overall dimensions of 24.5 m x 33.3 m x 4.1 m (L x W x H) including the service platform and a cladding of MDF boards coated on one side on three sides. In the grid system, stacks of 12 containers each are placed directly on the hall floor. Above the stacks of containers is the rail system (grid) on which the 32 battery-powered, autonomous robots move. The robots cooperatively pick up containers, re-sort them and are responsible for the supply and disposal of the carousel and conveyor workstations. The maximum total weight of the 649 mm x 449 mm x 330 mm (L x W x H) containers is 35 kg with a net load of around 30 kg. To ensure the maximum weight is maintained, an overweight check is carried out during storage. The containers can be flexibly subdivided by separating inserts for the use of several articles.

The system is controlled by the HiLIS AS warehouse management and control system, which was specially designed for AutoStore®. AutoStore® "only" knows the container number in the system, but not the contents. The higher-level WMS HiLIS AS knows the content of each container, takes over the higher-level management and control of the AutoStore® system and implements the logistical processes including the interfaces to the ERP system. The easy-to-understand graphical user interface of HiLIS AS provides clear work and picking instructions via touch screen. In addition, HiLIS AS supports permanent inventory processes, empty container insertion, status dialogues, special access to the containers and much more.

The AutoStore® small parts warehouse at Pati-Versand.de in Herzlake went into operation in early 2019.

Das AutoStore®-System besteht aus einem Aluminium-Rastersystem mit den Gesamtabmessungen von 24,5 m x 33,3 m x 4,1 m (L x B x H) inkl. der Service-Bühne und einer Verkleidung aus einseitig beschichteten MDF-Platten an drei Seiten. In dem Rastersystem stehen Stapel mit jeweils 12 Behältern direkt auf dem Hallenboden. Über den Behälterstapeln ist das Fahrschienensystem (Grid) montiert, auf dem sich die 32 batteriebetriebenen, autonomen Roboter bewegen.

Die Roboter nehmen kooperativ Behälter auf, sortieren sie um und sind für die Ver- und Entsorgung der Carousel- und Conveyor-Arbeitsplätze zuständig. Das maximale Gesamtgewicht der 649 mm x 449 mm x 330 mm (L x B x H) großen Behälter beträgt 35 kg bei einer Netto-Zuladung von rund 30 kg. Zur Absicherung des Maximalgewichts findet bei der Einlagerung eine Übergewichtsprüfung statt. Die Behälter können durch Trenneinlagen flexibel für die Nutzung mehrerer Artikel unterteilt werden.

Die Steuerung der Anlage übernimmt das von HÖRMANN Intralogistics speziell für AutoStore® konzipierte Lagerverwaltungs- und –steuerungssystem HiLIS AS. AutoStore® kennt „nur“ die Behälternummer im System, nicht aber den Inhalt. Das übergeordnete LVS HiLIS AS kennt den Inhalt jedes Behälters, übernimmt die übergeordnete Verwaltung und Steuerung des AutoStore®-Systems und setzt die logistischen Prozesse inklusive der Schnittstellen zum ERP-System um. Die einfach verständliche, grafische Benutzeroberfläche von HiLIS AS stellt via Touch-Screen klare Arbeits- und Kommissionieranweisungen zur Verfügung. Zusätzlich unterstützt HiLIS AS permanente Inventurprozesse, Leerbehälter-Einbringung, Status-Dialoge, Sonderzugriff auf die Behälter und vieles mehr.

Das AutoStore®-Kleinteilelager bei Pati-Versand.de in Herzlake ging Anfang 2019 in Betrieb.

ZURÜCK ZU DEN REFERENZEN

Richter + Frenzel has been the specialist for sanitary and building technology for over 125 years. More than 4,200 employees at 180 locations in Germany provide competent advice and planning with products from over 1,800 manufacturers. At the location in Reichertshofen, a new central logistics centre was built, from which R+F supplies branches and the trade nationwide. The central element in this new building is a fully automated warehouse solution for the storage and order picking of small parts. With its intralogistics concept, which includes an AutoStore® small parts warehouse with connected conveyor technology for order picking and palletising, HÖRMANN Logistik impressed and received the order to realise the system.

Concept

The new AutoStore® warehouse was integrated into a new building. In order to match incoming and outgoing goods or order picking to the flow of goods, the respective workstations were arranged on opposite sides of the AutoStore® system.

For the customised design of the AutoStore system for Richter + Frenzel, Hörmann Logistik carried out several system simulations with original data in real time during the planning phase. This also resulted in the recommendation for batch formation at goods issue/picking. The customer requirements, together with the simulation results, led to a system configuration with 45 robots, 50,000 totes on 16 levels and corresponding workstation modules.

The AutoStore® system consists of an aluminium grid system covered on all sides. In the grid system, stacks of 16 bins each stand directly on the hall floor. The rail system (grid) is mounted above the container stacks, on which the battery-operated, autonomous robots move. The robots cooperatively pick up containers, sort them and are responsible for the supply and disposal of the workstation modules.

The maximum total weight of the 649 mm x 449 mm x 330 mm (L x W x H) containers is 35 kg with a net payload of around 30 kg. To safeguard the maximum weight, an overweight check is carried out at the ports. In order to fill the containers in a quantity-optimised manner, Hörmann Logistik has implemented a self-learning system for weight and volume data. For each subdivision in the container (1/4, 1/2 or 1/1 container), only the same articles with the same properties may be stored.

The Hörmann Logistik warehouse management system HiLIS AS, which was specially developed by Hörmann Logistik for the AutoStore® systems, takes over the higher-level management of the system including all interfaces to the ERP system. The customer's picking and palletising robots also communicate with HiLIS AS via interface. All system data and functions can be called up clearly at any time via the HiLIS AS visualisation.

The new AutoStore® intralogistics solution at Richter + Frenzel went into operation in June 2019.

ZURÜCK ZU DEN REFERENZEN