News

Maximum performance and ultimate flexibility in logistics

30.04.2009

Ferdinand Gross and Dematic present a new, modular solutions concept.

Dematic, a market leader in logistics automation, and Ferdinand Gross, one of Germany's major suppliers of fasteners and connectivity technologies, and subcontractors to the machinery and equipment industries, have jointly developed a tailor-made and innovative storage and order fulfilment solution. The primary objective of the design was to enhance the level of customer service through a cost-effective distribution concept and expansion of storage capacities.

The core of this new distribution logistics design is the Dematic Multishuttle System, a goods-to-person concept which ensures substantially higher efficiency than the solution previously employed at Ferdinand Gross. In addition to a significant reduction in order throughput times from as long as 3.5 hours previously to as little as 30 to 60 minutes, the latest incoming order deadline has been moved from 12:00 noon to 15:00 hours. For customers, these changes mean considerably greater flexibility and improved services. At a delivery deadline established by the customer, all pending orders in the system are bundled into a single shipment. The resultant later order dispatch allows better bundling of individual orders, thereby reducing the number of packages to be consigned.

Thanks to the Multishuttle, highly dynamic picking achieves unsurpassed flexibility levels. The key feature of the solution realized for Ferdinand Gross is the world's first installation of the two Multishuttle versions, "Captive" and "Roaming", in a single storage unit with identical shuttles in both areas.

The Multishuttle Roaming system is dedicated primarily to storing those items most in demand by customers, improving availability and flexibility. The Roaming system delivers significant optimisation and cost-savings benefits compared to conventional solutions using automatic small-parts pickers. In the Roaming area, 20 shuttles serve the 55,000 storage positions at a throughput rate of 450 double cycles (parallel storages and retrievals) per hour. Every aisle contains one shuttle which accesses each level by lift and then runs on the rail to the selected storage position. The individual shuttles are transferred between levels via lifts - at impressive speeds.

The Captive area manages order picking of items from the roaming section, shelf storage system and picking-related logistics. Here, each level in the aisle is equipped with its own shuttle. The shuttles retrieves tote boxes from storage positions and convey them to a lift at the end of the lane. The lift vertically transfers the boxes to the out-feed conveyors which lead to the ergonomically-optimised picking station. Here, sequencing to customer specification is possible, i.e. delivery of good from inventory in the precise sequence that they are needed for picking in accordance with the order. In the captive area, 12 shuttles are operational, serving 5.000 storage positions at a rate of 500 double cycles per hour.

For Ferdinand Gross, the benefits of this customised future-proof system are manifold:

• Expansion of storage capacity by 60,000 positions: 55,000 in Roaming system and 5,000 in Captive system
• Improvement in order fulfilment times, extending order acceptance deadlines to the maximum
• Improvement of service performance thanks to the additional Captive lane. Sequencing to customer specification and individual labelling possible.
• Manual access to all storage positions in the Multishuttle
• Higher redundancy as items can be processed at any location and the workstations are completely decoupled
• One employee processes the entire order (improved traceability)
• Ergonomic workstations for improved operator performance and safety
• Concept is modular, facilitating future expansion at any time. As conversion took place in the existing footprint, potential expansion space outside of the existing buildings remains in reserve

Above all, it is the Kanban customers who benefit most from the new system: order fulfilment times are shortened tremendously, from an average of one week to just a single day. Previously, customers' shipping containers had a fixed label, showing article number, article description, amount and customer name. Once the customer emptied the container, Ferdinand Gross would pick it up and return it to the DC, ready to be refilled and shipped out again. With the new system, customer containers can now be relabelled for filling with any product rather than waiting for the original empty container to return to trigger the order. Consequently, return trips with empty boxes can now be bundled, reducing the number of trips to and from the customer. This cuts transport costs and has a positive impact on the environment.

Summary of logistics data and facts:

• Total of 120,000 shelf storage places, 20,000 pallet storage spaces at parent company in Leinfelden-Echterdingen
• 72,000 standard parts, 24,000 customer specific parts, 11,000 tools permanently on stock
• 5,000 order lines per day in forwarding department
• Approx. 40 tons each of incoming and outgoing goods each day
• Handling capacity: over 1,000 picks per hour
• Generous new bin warehouse: shelf height 12 m with 30 levels, shelf length 31 m, shelf width 19 m
• Multishuttle Roaming: 5 lanes with 20 Shuttles, 450 double cycles/hour
• Multishuttle Captive: upper 12 levels per lane, 12 shuttles, 500 double cycles/per hour