SCHAEFFLER ITALIA S.R.L.CARISIO (ITALY)

Case Study

PROJECT / CUSTOMER‘S REQUIREMENTSEUROPEAN DISTRIBUTION CENTRE EDC SOUTH

The industrial division of Schaeffler Group has restructured its global logistics. It is primarily directed toward Europe. 67 percent of the freight volume of the about 255,000 tonnes that the group shipped in 2014 was attributable to the desti- nations in this region. Through the project “European Distri-bution Centre” (EDC), a high-performance logistics network based on four locations in Continental Europe has been for- med. The project objective is to improve market supply to Europe and achieve optimised supplier performance. The EDC Middle located in Kitzingen, Germany, is the lo- gistics centrepiece of the future Schaeffler network. Two additional locations have already been completed. In March 2015, EDC North started operations in Arlandastad, Sweden.

In October 2015, EDC South started operation in Carisio, Italy. Completed by Aberle within only eight months as general contractor, the intralogistics are based on the planning concept from Metroplan Logistics Management GmbH in Hamburg.From material flow planning, controlling software and con-veyor systems to shelf construction and automation and on to the design and equipment of new, ergonomic workstations, the system supplier developed a best of breed solution for systems and components that are tailored to meet customer requirements. The system can also be expanded if there is additional growth.

Case Study SCHAEFFLER ITALIA S.R.L.

Shipping area with pallet storageOrder picking for automated sequencing

Automated small parts warehouse prezone System visualisation

Efficient material flow with intelligent space and surface use as well as optimally designed systems and components in the EDC South provide maximum goods availability, fast order processing and a high service level. Almost half of the warehouse space is available for pro- cessing and preparing incoming and outgoing goods. About one-seventh of the building area offers an op-tional expansion area for the shelving systems. The overall container conveyor system, the transport lines, storage tables and transfer stations for the auto- mated small parts warehouse are installed on a platform construction. As a result, the areas below it are largely barrier-free and can be used as transport and pro-cessing spaces. And: In addition to two workstations for processing incoming goods, Aberle set up twelve unique pick & pack workstations with the most modern ergonomics for the first time in the Schaeffler EDC South. At the new EDC, extendable PC stations, scales and

printers on the height adjustable worktables assist in screen-driven order picking and weight recording as well as the generating of shipping documents and labels. Twelve semi-automatic carton strapping machines that are harmoniously integrated into the workstations provide additional transport safety where needed. Vacuum hose lifters at all workstations sup-ports the employees. Two of the pick & pack worksta-tions are also equipped with chain hoists for loads up to 250 kg. Shipping packages are completed at the pick & pack station, including label and delivery docu-ments. Shipping pallets are packed and the finishing is done in a separate area. Overall, the system has increased goods availability and therefore the service level for the industrial after-market sector and OEMs. Together with the restructuring of the transport service providers and the use of syn-ergy effects, a significant reduction in run times has been seen.

BENEFITS / SPECIAL FEATURES

Solution

For the storage of items, Aberle has installed a four-aisle automated small parts container warehouse, a two-aisle order picker, and a four-aisle manually operated pallet ware- house. In addition, the EDC South has a separate area for storing long goods and hazardous materials. Sprinters and the containers for order picking are retrieved from the automated small parts warehouse and brought to a two-aisle picking area with 1,300 shelf spaces for double-depth storage. With its combi telescopes, the two fast stacker cranes provide up to 210 storages and retrie- vals per hour The order picker operates 12 new pick & pack workstations from Aberle.Based on special strategies, the order picker brings the containers in sequence to the conveyor system for the work- stations. At the pick & pack workstations, the required pallets are delivered with reach trucks. These pick & pack workstations, designed on the basis of an integrated modu- lar design and customised for Schaeffler, can be ergonomi- cally tailored to meet the service and design characteristics of the users and operators. In the shipping preparation area, the pallets are sealed at two specially developed workstation and secured with the help of the semi-automatic strapping machines. After weighing, the delivery papers and the labels are printed and the pallets are readied for shipping. The order consolidation and shipment preparation of the pallets is done at 230 marked pallet parking spaces in the goods receiving zone in front of the outgoing goods gates.

Integrated components

The goods flows are consistently separated based on pallet and container goods. During delivery the containers and trailers are unloaded by four high-lift trucks and buffered and verified in a processing area with 170 marked pallet parking spaces, and entered into the IT system. The entry is done in the customer’s SAP EWM system which also handles the upstream inventory management and the control of the work processes in the EDC. There one of the lift trucks takes the pallets and drives it to the deconsolidation workstations. In the deconsolidation area, all incoming pallets are processed. Items that can’t be placed in a container are manually transported by lift truck to a pallet parking spot in the manually operated shelf ware- house and recorded with a scanner. Long goods and large containers are transported to a separate area with a special four-way forklift. A total of 20 electric forklift trucks are in use. All electric forklift trucks are linked to the EWM sys-tems with a radio terminal from which they receive driving orders via WiFi. At the three repacking stations set up in goods receiving, appropriately sized items are put into containers individually, are joined informationally with the load carrier, entered into the EWM, and handed over to the container conveyor sys- tem. After they are linked with the individual container codes, the items are ready for automated handling and storage in the automated small parts warehouse. The container con-veyor system guides the containers to the transfer stations in the automated small parts warehouse. The material flow control is handled by the PMS-M module. It controls the conveyor system components for redundant distribution and storage of the containers in the automated small parts warehouse. The PMS-V module is used for the transparent visualisation of the automated warehouse processes.

Pick & pack workstations

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Case Study SCHAEFFLER ITALIA S.R.L.

TECHNICAL DATA

Aberle GmbHDaimlerstraße 4074211 Leingarten · GermanyPhone +49 7131 9059-0Fax +49 7131 9059-59www.aberle-automation.cominfo@aberle-automation.com

Industry Automotive

General Contractor Scope of Delivery - Order picking for automated sequencing - Manual pallet storage - Long goods shelving - Container conveyor sys. - 18 workstations - Crane system with vacuum hose lifters - Floor conveyors - Automation - Visualisation and material flow computer - Scales, strapping machine - Hazmat cabinet - Floor markings

Total usable space approx. 17,000 m²

High bay warehouse L x W x H approx. 31 x 28 x 9 mStoring positions 1,860 positionsWeight max. 1,500 kgType of storage single-depth

Small parts warehouse L x W x H approx. 50 x 16 x 10 mStoring positions 44,800 positionsWeight max. 50 kgType of storage single-depth

Stacker craneAisles / SRM 4 aisles /4 SRMsLoad handling device Telescoping tableHandling capacity 120 containers / h storages and retrievals

Order pickersL x W x H 5.5 x 7.2 mNumber 2 shelves /2SRMs with KTCStoring positions 1,300 positionsType of warehouse double-depth

Throughput max. 1,200 containers / h

IT-Base PMS-M / PMS-V