Completed WMS projects
Klug GmbH integrierte Systeme
Highly automated logistics centre for pharmaceutical wholesaler
Customers
FIEBIG
Completion
31.12.2006
Country
Germany
Branch
- Pharmaceutical industry
Description
Task description
Since its foundation in 1898, the regional pharmacists know Fiebig situated in Karlsruhe as a reliable partner. In order to maintain this status in the future, and also in order to react to smaller margins due to modifications in the law, the pharmaceutical wholesaler invested in a new logistics centre in Rheinstetten (near Karlsruhe). Fiebig itself found a solid and reliable partner in Klug integrierte Systeme to establish this new building as general contractor.
As the trade margin for pharmaceutical wholesalers was nearly cut in half because of the healthcare reform, Fiebig looked for an option to re-create its business processes more efficiently. Apart from a large range of SKUs and a fault rate of almost zero, the quality in delivery of the pharmaceutical wholesalers is mainly defined by the frequency the pharmacies are supplied and by short order cycle times. Fiebig not only wanted to increase their ability to deliver, but also that the new system should be future- proof, guaranteeing fast and reliable delivery and thus securing a decisive market lead into the future.
Fiebig took more than two years to find the optimal solution for the new logistics centre. Finally, they were convinced by the modular logistics concept iWACS® (integrated Warehouse Administration and Control System) by Klug integrierte Systeme, for it includes a universal view on the internal logistical processes: All processes in the warehouse are covered - from goods-in to dispatch. So, in cooperation with TGW, the partner for mechanics, Klug was able to realise all of Fiebig’s demands.
“Klug and TGW did not stick to old concepts, but have put together something novel based on both, our experience and theirs”, says Klaus Görke, CEO at Fiebig.
What is really new in this concept, is above all the high degree of automation of more than 90 % in the warehouse (for pharmaceutical wholesalers, about 55 % is typical). Apart from automatic picking of fast movers by means of A-frames, this is also attained by the automation of middle and slow movers. Each of the two A-frames is 65 metres long and is equipped with 1,800 shafts, each of which can eject up to six products per second. With the aid of a patented procedure, it is possible for the first time to stocktake the shafts permanently and automatically online. A new and also desicive feature is the automatic and continuous tracking of batches from goodsin up to the order tote. iWACS.HSP (High-Speed Picking) by Klug grants the smooth control of the A-frames. By means of a pick-to-light system, the individual shafts of the A-frame are selectively replenished. Due to a sophisticated replenishment strategy based on a sales forecast of the Klug host (iWACS.SCM), the system requires less personnel than the solutions reigning the trade up to now.
An innovative picking methodology (“flash pick”) for middle and slow movers provides a high picking capacity there also. The module iWACS.P2X (Picking) ensures the safe controlling of pick-to-light system and flash pick stations. An order cycle time of less than 15 minutes for orders with priority! - Garantueed by A-frames and flash pick stations.
This empowers Fiebig to supply particular pharmacies up to 5 times a day. The shorter the cycle time per order is, the larger the cruising radius of the pharmaceutical wholesaler will become, subject to the formula ‘number of customers = r² • л’.
But the capacity of these machines and automats, however, would be considerably smaller without the integrated onestop IT/ET solution (Klug/iWACS®). This solution brings out more of the sophisticated mechanical concept than conventional systems and unites man and machine to a homogeneous whole with regards to ergonomics and performance.
It is unique for a pharmaceutical wholesaler that not only warehouse management system (iWACS.WM) and material flow system (iWACS.MFC) come from the same supplier, but also the host system iWACS.SCM (Supply Chain Management). So, short paths between warehouse management and supply chain are granted. Apart from order registration, invoicing, goods-in, handling of returned goods, creating tours, ordering goods for replenishment, iWACS.SCMalso administrates the master data and supports Fiebig with forecasts and statistics.
The software modules have been installed on an IBM Unix Cluster with disaster recovery. This means that even in case a computer fails, the redundant backup system can take over the full functionality and maintain operation.
The new system is completed by iWACS.SIAM (Service Interface, Analysis and Monitoring). The service module keeps the user up-to-date about the system status and helps to ensure and evaluate the system functionality in the long term.
Contact person
Ramiro Martinez
Telephone: +49(0)9671 9216-0
markt@klug-is.de
