News
Four locations united: Hardinge Kellenberger relies on warehouse consolidation and digitalized processes with SSI Schaef
08.07.2024
6 SSI LOGIMAT® Vertical Lift Modules replace manual small parts warehouses with around 8,000 different components - Logistics area minimized by 35 % and material flow accelerated
Decision in favor of Switzerland as a high-cost location
Within the Hardinge Group, a leading international provider of innovative solutions for metal cutting, Hardinge Kellenberger AG, based in Goldach, Switzerland, has established itself as a pioneer in the manufacture of precision grinding machines since it was founded in 1917. In addition to KELLENBERGER, the brands on offer include VOUMARD, HAUSER and TSCHUDIN. In 2021, the company decided to take a significant step towards digitalization and modern warehouse logistics with optimized space utilization and to merge four production sites in a new plant to be built in Goldach to be able to continue to produce lucratively in a high-cost location such as Switzerland in the future. The relocation took place in July 2023 during ongoing operations.
Tangible requirement: Double it!
Double it! That was the management's brief. To be more precise, the aim was to double production capacity, merge the four existing production sites into one new building and digitalize the logistics processes to make them highly efficient. The aim was to achieve a lean and transparent material flow in Hardinge Kellenberger's synchronized machine assembly. In collaboration with intralogistics specialist SSI Schaefer, a concept was developed to implement these requirements at the future site in Goldach.
Intralogistics solution based on SSI LOGIMAT Vertical Lift Module
SSI Schaefer Vertical Lift Modules (VLM) will play a key role at the new site. Thanks to the compact vertical design of the VLM and the use of the hall height, an enormous storage density was achieved, and the total logistics area was reduced by 35 %. A total of 6 VLM and the WAMAS Lift & Store software were implemented, which help to digitalize the processes and optimize the material flow for assembly supply. The additional installation of cantilever and PR 600 pallet racking has created further compact storage space for pallets and long goods.
Vertical Lift Modules guarantee fast material availability
Before moving into the new warehouse in Goldach, employees in the assembly area spent too much time searching for items in different locations and on several floors. In addition, errors occurred when, for example, the number of items in the warehouse did not match the ERP system. Stocktaking was also becoming increasingly time-consuming and inefficient. With the small parts storage of around 8,000 different components consolidated in the VLM, fast material availability is guaranteed in future.
Game changer in small parts storage for assembly
Saving space, gaining efficiency, increasing ergonomics, and digitizing and accelerating processes - the SSI LOGIMAT Vertical Lift Module is an ideal solution for storing small parts in an extremely compact way on a small footprint using the building height and still ensuring fast access. The range of products required forassembly at Hardinge Kellenberger is particularly suitable for storage in a VLM system, as it involves a high customer-specific diversity of parts and variants, with components that vary greatly in size and weight and are often highly precise and sensitive and therefore need to be stored and handled in a particularly clean and protected manner.
Special features for smooth and ergonomic processes
The 6 SSI LOGIMAT Vertical Lift Modules are operated by an average of 3 employees. In addition to the intuitive operator guidance on the touchscreen, two features ensure particularly efficient and transparent picking: the use of the LOGIPOINTER with its built-in laser pointer ensures that the product to be picked is marked, making incorrect picking virtually impossible. The entire process is confirmed by a continuous confirmation light barrier under the operating opening (LOGIBAR). Ergonomics have been further improved with LOGITILT. In addition to the individually adjustable removal height, the trays in the removal area can also be tilted by up to 30° to make it easier to remove parts from the rear tray areas. The features are complemented by safety functions such as weight and height monitoring. Also worth mentioning is Hardinge Kellenberger's intelligent distribution of the same items across several VLM to ensure that access to the required items is guaranteed in the event of maintenance or even a VLM failure.
Seamless integration of WAMAS Lift & Store into the existing ERP system
The WAMAS Lift & Store software controls the VLM. It was simply connected to the existing ERP system and combines master data, order and inventory management in a single software package. Integration takes place in real-time and, thanks to the direct connection and communication with the ERP system, stock management, material planning and booking can be carried out in one central location. This ensures optimum management that meets the requirements of modern and efficient warehouse logistics and includes inventory and reporting functions. In addition, processing is paperless in the long term.
Precise adherence to deadlines
Hardinge Kellenberger had set itself the goal of carrying out the relocation during ongoing operations without any loss of production. This not only placed high demands on the project management but also on the reliability of the contracted companies. SSI Schaefer was able to meet the required time frame precisely - thanks to flexible and cooperative collaboration. It took just six weeks from the start of installation to handover, including software training. Rico Bonaconsa, Director of Order Fulfillment Process at Hardinge Kellenberger, comments: »We worked hand in hand and coordinated closely to ensure that the relocation could be carried out during ongoing operations and within a short time frame after the construction phase. For example, the employees were trained on the SSI LOGIMAT Vertical Lift Modules from SSI Schaefer while the shelves were filled in the background.«
Future-proof warehouse logistics
Viktor Gaspar, CEO of Hardinge Kellenberger AG, is also pleased with the successful move to the new plant in Goldach: »By optimizing our warehouse logistics, we have achieved a significant improvement in production processes and a more efficient supply of our production lines. As a result, we are already achieving significant increases in capacity and efficiency. The VLM are currently around 60 % full. Through ongoing optimization, we expect to increase efficiency by up to 20 % in the coming months.« Approaching the »double it« target in terms of production capacity is likely to be the next step.