Logistics revamp supports faster and more flexible spare parts deliveries

Heating systems manufacturer Weishaupt has invested over 30 million Euros over the past two years in modernising its logistics centre.

The existing warehouse for spare parts and production logistics in Schwendi (AS/RS) was in operation for 24 years. With an occupation rate of more than 90%, the AS/RS was operating at the limits of its capacity. The quantities and ordering behaviour of customers had also changed considerably over the years. 

In order to meet these increased requirements in the future, a Weishaupt project team designed and implemented a new storage concept together with the Witron to implement a high degree of flexibility and short delivery times. Every order received by 6pm is shipped by 7am the next morning at the latest.

The solution was the automated picking system OPS (Order Picking System). It is an integration of an automated small parts warehouse (AS/RS), a distribution loop, and upstream picking workstations. The products processed at the OPS picking workstations are made available for picking according to the goods-to-person principle – order-related and in the right sequence. 

“Integrated sequence buffers decouple the inbound and outbound processes from the picking process”, explains Josef Gallersdörfer, project manager from Witron.

The system enables storage and order picking in one system.

“OPS is particularly interesting for spare parts distribution, as the system supports a wide variety of picking variants. In addition to a serial 1:1 order picking, it also enables a parallel picking into several order totes.”   

The twelve-aisle AS/RS – six aisles on two levels – including 83,000 storage locations was rebuilt and moves 41,000 totes daily. It is connected to the existing logistics and production areas via a connecting catwalk.

The employees carry out fewer secondary activities. For example, the system automatically handles empty totes. Employees also benefit from the improved ergonomics of the picking areas. Height-adjustable workstations, plenty of daylight, tilted totes, and transparent user dialogs make work easier. “Visual aids and integrated scales guarantee high pick accuracy and quantity”, adds Gallersdörfer. The Weishaupt employees were also trained to master a large number of workstations in different logistics areas.  

By separating the tote flows at the picking workstations from orders with only one item and orders comprising several items, as well as the parallel picking of two orders, flexibility could be significantly increased. In addition: Through the intermediate buffering of pre-picked orders, which have a different delivery date than the actual date, it is possible to pack the current orders shortly before they are shipped. Weishaupt can pick, pack, and ship up to 1,950 spare parts packages daily in its new logistics centre, optimised through a volume calculation so that little “air” is shipped. 

A new WMS was implemented, interfacing to SAP, a production control system, transport systems of service providers, and to the entire Weishaupt network structure.  

The technicians operated an old system under full operation and installed the new conveyor system lines at the same time. Above all, supplying the production area presented the project partners with ever new tasks – such as in the basement area, where it is narrow and difficult to access. Gallersdörfer and his team installed the new conveyor system next to the old systems, linked the old warehouse management computer with the new one, and ported the controls from S5 to S7 so as not to have to manually reposition the totes in the pre-stage of start-up. 

“The initial parallel operation of the old and new system, allowed the performance of the new system to be increased selectively during ramp-up”, adds Gallersdörfer. 

During the entire construction period, the installation area was shielded off so that dust and dirt did not interfere with the neighbouring production area and the existing AS/RS.