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KNAPP's OSR Shuttle for Würth Industrie Service

21.03.2011

KNAPP was awarded the order for the installation of an OSR Shuttle at Würth Industrie Service GmbH & Co. KG, supplier of logistical supply and service concepts for industrial customers, at the Bad Mergentheim location in Germany

The special requirements of this industry resulted in the premier of a highly-dynamic Shuttle System with the capacity to process containers of up to 50 kg. In time for Würth Industrie's Open House Days on September 17 and 18, the system will Go Live in the beginning of September, which requires a strict time schedule and perfect coordination of all suppliers involved.

High loads and low tolerances

Würth Industrie Service supplies industrial customers with modular logistics and procurement solutions for connection and fastening elements. The goods are delivered in small-load carriers (W-KLT, KLT, material: plastic), used by the customer for stocking flow racks in assembly-line production. This Kanban principle makes it necessary to transport the goods in the containers as bulk material, with a weight of up to 50 kg per container. "Bulk material is especially problematic with high transport speeds and gradients. For example, 25 kg of washers in a transport container can behave like a viscous fluid. Therefore precise control of the system is absolutely necessary and represents one of the big challenges in this project," said Mag. Börge Schlingmann, project manager at KNAPP Systemintegration GmbH.

Great potential for expansion

The core of the KNAPP order processing system is the OSR Shuttle. The OSR Shuttle includes four aisles (two next to each other and two stacked on top of these), which are all independent of one another and designed with redundancy. The capacity of the first installation phase has 64,000 storage locations for containers sized 600 x 400 mm. An article group can therefore be accessed in more than one aisle. Even if the line transporting goods out of the OSR fails, because of the system redundancy, goods can be transported out of the OSR to dispatch on the goods-in line.

Growth is foreseeable in the coming years for the warehouse in Bad Mergentheim, therefore during the planning phase emphasis was laid on including possibilities for expansion. KNAPP's shuttle system has been planned for expansion both in terms of aisle length as well as number of aisles. A threefold increase in the number of storage locations in the future is therefore possible. In order to manage this increased volume, the number of work stations can be doubled making up to 100,000 order lines per day possible.

Twelve multifunctional work stations

In the first phase twelve multifunctional ergonomic work stations will be integrated. All twelve work stations are identical, and can fulfil five different functions: picking, checking and shaking, consolidating, and goods-in and goods-out processes.

During checking and shaking the picked items are automatically filled into a small load carrier after a successful weight check. The W-KLTs/KLTs are labelled according to customer and are sent back to storage in the OSR Shuttle for dispatch preparation. Along with the many commercially available standard KLTs, Würth Industrie Service also employs their own specially developed and patented KLTs. Empty cartons generated in this process step are transported from the work stations through ergonomically situated shafts to an underlying take-away conveyor for further use or recycling.

To best use the warehouse capacity of the OSR Shuttle it is possible to consolidate various small load carriers of a customer order on the warehouse trays.

Test installation delivers additional assurance

Based on the test installation in March the work stations and critical sections of the conveyor system will be tested in regards to the special requirements (50 kg, incline, acceleration). Test results in hand, the optimal control processes for the entire warehouse will be developed.

KNAPP Systemintegration GmbH

KNAPP Systemintegration located in Leoben (Austria) is the specialist within the KNAPP corporate group for all-in-one logistic solutions in complex and highly automated warehouse areas. The core competencies of the company lie in the conceptualization and the development of complete logistical solutions and their realization as system supplier and general contractor.

The business activity ranges from integrated analysis of business processes and professional consulting, planning, programming, manufacturing, the entire installation and startup up to technical system operation including provision of required staff and necessary training of employees. KNAPP's 24-hour hotline guarantees the optimal operation of the warehouse at all times.

Würth Industrie Service GmbH & Co. KG

Würth Industrie Service GmbH & Co. KG, a member of the Würth Group, is part of a globally-active industrial network (WINWORK®) with emphasis in Europe, North America, and the Pacific, to support the new demands of major customers who are nationally and internationally active.

Würth Industrie Service, as complete C-class inventory supplier, presents a specialized product array of more than 420,000 items to its customers: screws, connectors and fasteners to tools up to chemical-technical products. In addition to the extensive standard range, the core competence lies in customized logistics and operational supply and service concepts and custom parts development.

Long term partnership

The Würth Group and KNAPP have realized numerous projects together, which have always involved systems with complex processes. KNAPP has accompanied the Würth Group all over the world, and places a special emphasis on always using the same project team, guaranteeing each project optimal cooperation from the very start. The OSR Shuttle at Würth Industrie Service GmbH & Co. KG represents a further milestone in a long-standing partnership.



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