frischli Milchwerke GmbH is one of the most modern and efficient dairies in Germany. For over 100 years, the owner-managed company with headquarters in Rehburg/Loccum near Hanover and sites in Weißenfels and Eggenfelden has been producing dairy products. Over 750 farmers from the respective regions of the three sites supply the basis for the numerous products such as long-life milk, milk powder and cream. Due to continued growth, frischli is currently expanding its production capacities. frischli and viaLog have been working together since 2005 to develop production and distribution logistics.
From master plan to realisation
Initially, the food producer assigned theadvisors from viaLog with the creation of a master plan, to extend the factory in Loccum.
The task
Since the 60s the dairy has grown continuously. With a monthly delivery of 25,000 tonnes and a dispatch of approx. 1,200 pallets per day, the capacity limits of the existing technology have already been reached. In addition to expanding production, the task was to integrate the packaging materials, some of which had been temporarily outsourced, into the Loccum plant. It was also necessary to overcome bottlenecks in the space and picking bays in the dispatch area. Finally, the WMS that had just been introduced was to be optimised and functionally supplemented.
Firstly, strategic planning was required with a view to the medium and long-term expansion of the site. The master plan drawn up for this purpose described, among other things, ways for a coherent material flow, layout planning for the maximum expansion and the realisation of the expansion during ongoing operations. Subsequently, the planning of a new storage system and picking system for finished products and packaging materials was carried out in detail for the first expansion stage (2010 scenario). The building, technology, personnel deployment and investment were determined according to the “form follows function” principle.
The concept planning was carried out in the classic three-step process: basic evaluation, system alternatives, implementation proposal. The planning results were discussed in regular meetings with the management.
The concept
On the recommendation of viaLog, frischli decided in favour of an automated high-bay warehouse with satellite technology and storage of the packaging material in a mobile rack. The decisive factors for this decision were
- qualitative aspects such as low space consumption, the possibility of realisation during ongoing operations, staff cohesion and flexibility for storage and order picking
- the low total running costs from investment and personnel
- an acceptable level of investment
Conclusion
The project made it very clear how cost-saving and effective a manufacturer-independent decision-making process is for users. The range of existing technology alternatives is also far greater than that of a single manufacturer. As is so often the case in the planning business, this has also been demonstrated at frischli: Comparisons of figures alone, e.g. of investment, personnel and costs, do not reveal the optimum concept. The overall cost-effectiveness of different alternatives is often comparable. Only the in-depth discussion of the qualitative advantages and risks of different solutions makes it possible to determine the optimal and correct concept.
Automatic channel storage system
viaLog was commissioned to plan an automated channel storage system including connecting conveyor technology.
Planning and procurement of filling, palletising and conveyor technology
viaLog is currently supporting the dairy in the planning and procurement of filling, palletising and conveyor technology.
Realisation of high-bay warehouse extension
In 2005, viaLog drew up a master plan for the expansion of HRL capacities for the Rehburg-Loccum site. The first construction phase of the HBW expansion was realised in 2006. In January 2012, the 2nd construction phase of the HBW with approx. 3,400 pallet spaces was awarded. Assembly of the steel racking is scheduled to begin in mid-July this year.
Logistics expansion Weißenfels
viaLog was initially commissioned to draw up a master plan for the entire plant and, based on this, to plan the expansion of packaging and finished goods logistics in detail.