HAZET-WERK Hermann Zerver GmbH & Co. KG is a well-known manufacturer of quality tools and workshop equipment. From its logistics centre in Heinsberg, the Remscheid-based company dispatches more than 1,000 parcels a day from a range of over 5,500 products. Orders received by early afternoon are dispatched on the same day.
viaLogs projects with HAZET
Concept planning for central warehouse
Planning, tendering and commissioning of a warehouse extension
Concept planning for central warehouse
viaLog was commissioned to develop a concept plan for the expansion and optimisation of the central warehouse at the Heinsberg site.
viaLogs projects with HAZET
Concept planning for central warehouse
Planning, tendering and commissioning of a warehouse extension
Planning, tendering and commissioning of a warehouse extension
The challenge
Exhausted capacities, no end-to-end IT support and a non-transparent consolidation process – the family-owned company was confronted with several difficulties at once. Ongoing company growth put additional pressure on logistics.
The task
HAZET commissioned viaLog with the optimisation and expansion of its logistics in Heinsberg. The planning and consulting company carried out the planning for the logistics of the existing warehouse and the new building. In addition, viaLog managed the tendering, realisation and commissioning of logistics technology and IT.
The solution
The additional storage capacity was accommodated in an extension of approx. 4,800 square metres of logistics space. After a realisation phase of just 13 months, the facility went live.
Expansion of capacity
To increase storage capacity, the pallet storage capacity was increased from 1,745 to 3,993 storage locations. The container warehouse was expanded from 11,874 to 16,571 storage locations.
Reorganisation of order consolidation
Until now, the consolidation process had been solved organisationally. To optimise this, two automatic walking beam small parts warehouses were implemented as the centrepiece of the warehouse extension. With 600 bin storage locations each, they serve as a buffer between picking and despatch. They automatically supply the 16 packing stations with picked goods only when all components of an order are available. Consistent mapping in the warehouse management system (WMS) helps to optimise the process.
WMS upgrade and process optimisation
As part of the process optimisation, HAZET switched from SAP WM to SAP EWM. Material flow control is now also carried out via the WMS. Christoph Jung, Head of Logistics at Hazet, is delighted with the increase in performance: “New hardware and software as well as a completely redesigned workflow now ensure even more efficient processes and fast order processing.”
The highlights
Moderate mechanisation = minimum investment + maximum flexibility: “As much technology as necessary, but as little as possible” – with this planning principle, viaLog kept Hazet’s investments to a minimum. At the same time, this planning approach allows the warehouse to be designed as flexibly as possible for future changes.
Synchronisation for lean logistics: A logistics concept covering all areas ensures that throughput times, buffer areas and warehouses are minimised.
Double security: Picking by image and sound Previously, a conventional mobile data acquisition (MDA) system controlled the picking process. Hazet decided to switch to pick-by-voice. As many items are very similar, a photo of the picking position is displayed on the MDE terminals in addition to the audio signal. This double safeguard minimises the error rate in the picking process.
Warehouse profile
Type: Distribution warehouse
Stored goods: Quality tools, workshop equipment
Logistics space: approx. 11,000 square metres
Products: ca. 5,500
Positions / Day: Ø approx. 5,000
Storage locations: approx. 21,000
Conveyor technology: approx. 225 running metres
viaLogs projects with HAZET
Concept planning for central warehouse
Planning, tendering and commissioning of a warehouse extension
Distribution study
The task
HAZET distribution is characterised by growing delivery service requirements of the automotive industry. Logistics had become closely interwoven with the sales function of the dealerships. It was measured by individual standards, developed differently from region to region and only partially met the requirements. The time for an overhaul of the entire logistics system seemed to have arrived at the beginning of 2001.
The viaLog performance
The first step was to determine the optimum level of service and centralisation. This was done in a three-month study. viaLog then developed the optimum warehouse concept for Heinsberg. This was followed by the tendering and awarding of the warehouse management software, including dispatch processing and radio data transmission, as well as the tendering of the conveyor technology. All the systems were then put into operation.
The solution
The result of the distribution study: concentrating national distribution at the warehouse in Heinsberg offers clear service and cost advantages. To this end, the Heinsberg warehouse had to increase its efficiency. All components of modern warehouse logistics were realised:
- Paperless picking
- Wireless data transmission / Pick-by-Light
- Pick & pack processing
- Comprehensive support by means of warehouse management under SAP R3 including package pre-determination, batch creation, optimised allocation of dispatch packing stations and connection to an external dispatch system.
With the central warehouse “tuning”, the decentralised sales representative warehouses were gradually dismantled. HAZET distribution was transformed into modern logistics processing and now fulfils the highest requirements.