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GEBHARDT Automates New Parts Warehouse at DIEFFENBACHER

25.07.2025

Enhanced Transparency, Throughput, and Future-Proofing on 300 m².

DIEFFENBACHER GmbH Maschinen- und Anlagenbau from Eppingen relied on automation solutions from GEBHARDT Intralogistics Group for the new construction of its parts warehouse. An automatic storage system was implemented, optimising the process for goods receipt and order picking.

The GEBHARDT Intralogistics Group has successfully implemented a highly automated small parts warehouse for DIEFFENBACHER GmbH Maschinen- und Anlagenbau. Utilising a shuttle warehouse, intelligent software, and advanced conveyor technology, this project exemplifies future-proof intralogistics in mechanical engineering, achieving up to 220 double cycles per hour with complete SAP integration.

Initial Situation: Warehouse at Capacity Limit

DIEFFENBACHER’s existing warehouse faced challenges due to outdated structures, manual processes, and limited storage capacity, which created bottlenecks in the processing of incoming goods and order picking. The absence of system integration complicated efforts to establish end-to-end process and inventory transparency. The goal was to implement a flexible and high-performance automation solution that combined efficiency and scalability.

Solution: Highly Automated Shuttle Warehouse with Intelligent Roaming Concept

The centrepiece of the new system is a single-level shuttle warehouse covering approximately 300 m², organised into 17 levels across three aisles. It features 8,976 container storage locations and employs a roaming concept supported by vertically movable shuttle lifters, allowing for an output of up to 220 double cycles per hour. This design enhances throughput while optimising energy and space utilisation.

Increased Efficiency Through Seamless System Networking

The system features four ergonomically designed goods-to-person picking stations and modern conveyor technology, including automatic weight and contour checking. The GEBHARDT StoreWare warehouse management system centralises the control, documentation, and optimisation of all processes. A direct connection to the existing SAP system ensures consistent data transparency and process reliability.

Implementation During Ongoing Operations

The installation was conducted in several phases. Initially, the first lane was constructed alongside the existing system and put into operation. Following the dismantling of the old structure, two additional aisles were built, leading to full commissioning by the end of 2024. Throughout this period, production remained uninterrupted.

Result: Enhanced Performance, Transparency, and Future Viability

The new solution delivers reduced throughput times, increased inventory security, and flexible scalability to accommodate a growing range of parts. It enables DIEFFENBACHER to elevate its spare parts logistics to a future-proof standard.

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