Glasses in all shapes and colours, jewellery and decoration – this is what glaskoch B. Koch jr. GmbH + Co KG is internationally recognised for this under the Leonardo brand. From its Bad Driburg site, glaskoch delivers to 83 countries via multi-channel logistics. The logistics centre supplies both its own branches and well-known retail chains. Since 2007, end customers have also been able to order goods directly via the online shop.
Implementation of a new warehouse management system
In order to optimise the efficiency of logistics processing, the wholesale company commissioned the consultants from viaLog to design, tender and implement a new warehouse management system.
Performance audit for paperless picking
viaLog was commissioned to carry out a performance audit on the use of a warehouse management system.
Area optimisation
The initial situation
The existing eastern warehouse in Bad Driburg with approx. 3,150 square metres and a clearance height of approx. 8m was used for a long time as a floor block warehouse with approx. 2,000 pallet spaces for the storage of raw materials and promotional goods.
However, the capacities at the Bad Driburg site were no longer sufficient. External warehouses had to be rented. The number of sales promotions for promotional and seasonal items was to be significantly increased – with all the demands placed on order picking.
The solution
After collecting the basic data, determining system alternatives and drawing up an implementation proposal, glaskoch realised the project in collaboration with viaLog at the same time as converting a high-bay warehouse.
The new racking system with approx. 3,000 pallet spaces consists of a total of 6 storage blocks. In order to achieve a high fill level in the system, the storage channels have been designed with different depths of 2-7 storage locations. Conventional pallet racking (1-deep) is also used in addition to the storage channels so that items with a total stock of only one pallet can be stored in a space-saving manner.
Special feature here: ViaLog picking tunnels integrated into two storage blocks for picking promotional goods. For replenishment, the pallets are lowered from the storage channels above the picking tunnels into the flow channels of the picking tunnel.
Two manual reach trucks are used in the sewer warehouse. To operate the lanes, the reach truck positions itself in front of the rack and places the lane vehicle in the respective lane. In the lanes, the lane vehicle moves independently of the reach truck using its own drive and lift motors.
Another element: In order to achieve optimum space utilisation, the goods receiving area was covered with a 500 m² steel construction platform. Today, the WE pallets are buffered on the ground floor. Packaging materials and slow-moving items are stored in block storage on the upper floor.
The highlights
- Reduction of external storage through optimal space utilisation in the East Hall (compact storage and platform)
- Compact and flexible storage form thanks to the use of storage channels with different depths and the addition of conventional pallet racking
- Aisle separation of replenishment and order picking through the use of pallet flow channels
- Short distances for replenishing promotional goods in the flow channels
Logistics controlling
The task
The existing reporting system consisted of many analyses and presentations that were created independently by the individual departments (goods receipt, warehouse, dispatch, etc.). viaLog was commissioned to develop a proposal for a systematic reporting system. The solution was to be implemented using Office products (MS Excel, MS Access).
The solution
The basic idea of the controlling approach is the planning of logistics performance for quantities, costs and productivity. The logistics reporting system, according to viaLog’s realised proposal, was divided into two “hemispheres”:
- Key figures for logistics management
- Key figures for the operating divisions
For logistics management, key figures such as throughput, productivity, personnel and picks are clearly displayed in the planned/actual comparison. The new logistics controlling tool increases the level of detail of the information at the operational level. Here, individual process steps (e.g. unloading containers or picking with labelling) are viewed separately. Data is generated via interfaces (e.g. from the WMS, ERP) and manual entries by those involved in the process.
Resume
The result is an innovative tool for planning and controlling logistics cost drivers.
Modernisation of the existing high-bay warehouse
The task
glaskoch has been operating a manual six-aisle high-bay warehouse (HBW) with approx. 10,000 pallet spaces for 30 years. The high-bay warehouse is managed with a man-operated storage and retrieval machine (SRM) with transfer unit. Due to growth, the system was no longer up to the current task. Technical bottlenecks – such as a lack of dynamics and incorrect shelf heights in the racking – led to increased personnel deployment and the severe limitation of storage capacity.
The solution
New technology for existing building
With the complete modernisation of the system in the existing building, the problems could be solved quickly, effectively and cost-effectively.
Floor conveyor technology
At viaLog’s suggestion, glaskoch replaced the existing manned storage and retrieval machine (SRM) with a fully automated SRM. The SRM transfer unit is now supplied and removed via a double distribution trolley, which is connected to the new storage and retrieval conveyor system of the HBW. To decouple the storage and retrieval conveyor technology, up to six pallets can be buffered on the transfer unit – three on the storage side and three on the retrieval side. The required material flow computer has been connected to the existing WMS for this purpose.
Shelf system
The structural design of the hall/shelving system made it possible to remove cross beams. This allowed the number of high storage spaces in the high-bay warehouse to be doubled. However, the organic expansion of the logistics centre for future growth has also been considered: the new east hall is to be connected to the high-bay warehouse via a conveyor bridge. Provision has also been made for the use of a second SRM with a second transfer unit. Following planning, examination of the system alternatives and detailed planning, the new high-bay warehouse was realised in 2006 and went into live operation in September 2006.
The highlights
viaLog consultant Klemens Hartmann describes the highlights of the project as follows:
- Doubling the dynamics by replacing the technology and developing intelligent storage and retrieval strategies
- Continued use of the RBG and transfer unit rails through cost-effective reprofiling
- Minimising the downtime of the HRL by carrying out some of the conversion work in parallel with ongoing operations.