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Well-prepared for the future with retrofit and expansion of storage capacities


Medical device manufacturer Ofa Bamberg expands and retrofits logistics center

As one of the leading manufacturers of medical compression stockings, orthopedic supports and ortheses with about 600 employees and a success story extending over 90 years, Ofa pursues a clear demand: maximum comfort and attractive looks at best effect. The product design of Ofa won numerous international awards.

In order to meet the requirements of the market, Ofa Bamberg expands the existing warehouse technology and undertakes an extensive retrofit of its logistics system. With the expansion of the existing building, the specialist for medical products sends a signal with regard to speed, availability and optimized material flows - without disruption to the ongoing operation by the required expansion work. The retrofit and expansion have been planned in detail together with the intralogistics system integrator Klinkhammer. The automated high-bay warehouse including control technology is retrofitted and expanded by an automated, double-deep container warehouse with 2 aisles. Thus, Ofa is well-prepared for future logistics requirements. In the course of alteration works, a new optimized warehouse pre-zone with connected, space-saving order picking loop is built. The already existing material flow and warehouse management software is replaced by the Klinkhammer warehouse-management-system KlinkWARE®, which is connected to the existing ERP-system.

A coordinated, multistage, production-oriented alteration concept guarantees a smooth relocation during the ongoing production process. The multistage concept comprises a two-aisle expansion of the entire system while the old system remains fully functional. After the expansion has been put into operation, the stocks are transferred from the old system. Then the old system is retrofitted. An interim conveyor loop is installed which is expanded in the second stage of construction. The multi-level conveyor technology currently in place is now merged on one level in an order picking loop to save space.

»With such complex structures, a detailed alteration planning and close coordination between the planning and project management team of the Klinkhammer Group and our own project team is essential,« explains Björn Schwinn, head of warehouse logistics at Ofa Bamberg. »The optimized interlinking of sections during ongoing operation requires a strong project management on all sides«. In addition, the alteration in the existing building takes place in particularly confined conditions and therefore requires a detailed planning concept which takes Ofa production into consideration.

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