Increasing efficiency and gaining space in existing building
Confined space conditions often restrict the scope when modernising warehouses. SSI Schäfer solved these structural challenges, which are particularly widespread among smaller and medium-sized companies (SMEs) with the installation of SSI LOGIMAT® warehouse lifts at WFL Millturn Technologies. By increasing the storage capacity for small parts vertically, it was possible to free up a remarkable 110 m² of floor space in the existing hall. The devices are controlled directly from SAP, which means that sub-systems and interfaces are not required. The successful machine building firm has also recorded an increase of up to 50% in picking output in this area.
Based in Linz, Austria, WFL Millturn Technologies GmbH & Co. KG is the only manufacturer worldwide that concentrates exclusively on the production of multifunctional complete machining centres. Every individual complete machining centre supplied under the MILLTURN brand is a special machine. Consequently, the current stock levels, which stand at around 30,000 active articles, including spare parts, will continue to increase in future – not least thanks to new machine types such as the M20 MILLTURN.
Focus on process changes
Alexander Hofmann became Head of Logistics Operations at WFL in 2019. His job is to stay abreast of the increasing logistical challenges and develop new approaches to optimisation. In this way, for example, standard drawer cupboards have largely been used to store small components. Even though, in line with WFL’s SAP strategy, warehouse management software was and is in use with SAP WM, the question of where to find free storage space became increasingly impossible to answer. The different sizes of the compartments in the drawer cupboards also caused issues as they had to be repeatedly adapted to fit the stored goods. Process times became longer and space in the warehouse became increasingly tight.
Modernisation of small-parts storage through partial automation
In order to get to grips with this problem, SSI LOGIMAT® warehouse lifts from SSI Schäfer were sought out by WFL from the very beginning, as they enabled partial automation of small-parts storage and picking: “We were looking for a solution that is tailored to our requirements. The one we found is so successful that it is now an established system in the market which can store a wide range of different materials in very little space and, moreover, is intuitive to operate alongside being robust and reliable,” stresses the Head of Logistics. SSI Schäfer’s software skills in conjunction with the SAP expertise of system partner Status C, which is unique on the market in this specification, was key to placing the order. “We didn’t want any additional software that would be connected to additional interfaces, as that would involve maintenance and update costs – we wanted to work directly in SAP. Status C has provided the perfect solution that is tailored to our individual needs,” continues Hofmann.
Installation while retaining structural integrity
The order to supply six SSI LOGIMAT® warehouse lifts including integration into the existing SAP environment was placed at the start of November 2019. The warehouse lifts were then installed in the existing building in January 2020. “However, we then had to overcome a number of structural challenges,” says Alfred Spicker, Head of Dynamic Systems, Products & Equipment business unit, at SSI Schäfer. “The existing platform practically had to be cut out in order to enable installation of the automated storage and picking systems. WFL also took this opportunity to redesign the platform and optimise it.” SSI Schäfer provided further support with finding the concept and selecting suitable storage containers as well as with the process of relocating initially around 12,000 of the some 15,000 articles in the small parts area.
Storage density increased vertically to 70 m²
Things started to ramp up in April 2020. Prior to this, the old drawer cupboards were relocated to alternative areas and the new warehouse lifts were also filled during ongoing operations without significant restrictions. The current SSI LOGIMAT® system consists of two rows with three devices each, with the dimensions 3.8 x 3.1 x 7.3 m (L x W x H). They are fitted with 58 trays (3225 x 815 mm) and enable loads of up to 550 kg. 64 trays can be switched per hour for each lift. Around 15,000 LMB containers are in use. LMB containers are specially designed by SSI Schäfer for use in warehouse lifts and have been optimised to the shelf board depth of 800 mm. Four different types of container from the LMB range were selected, which can be varied within a tray and divided by means of robust partition walls. This enables fast, simple assignment of articles and prevents products from being sifted through and mixed up. The trays provide a direct overview of the parts to be removed, while the containers are accessed manually from above, making them ergonomic and eliminating any tiresome stooping and stretching in day-to-day work. The additionally initiated batch picking system enables WFL to process multiple orders simultaneously, which has significantly increased picking output even further.
Warehouse lift control in SAP without third-party system
SPS EasyConnect was used to enable the SSI LOGIMAT® warehouse lifts to be integrated directly into WFL’s existing SAP environment. This SAP add-on from partner Status C enables a direct connection without additional sub-systems. “All of the functions of the warehouse lift are mapped in it,” explains Alfred Spicker. “Transport orders generated in SAP are thereby visualised on the lifts in real time and converted into tray movements.” The direct lift control makes processing of the order queue faster by hand, further supported by user-friendly touchscreens that can be operated intuitively. SPS EasyConnect further ensures maximum stock reliability. There is no duplicate inventory management, and future software updates from SAP are incorporated straightaway.
Prestige project as the basis for further optimisations
“We are delighted with the results achieved,” concludes Alexander Hofmann. “SSI Schäfer and Status C have delivered us a solution that meets our exact requirements. The collaboration and implementation went very well, despite a few challenges.” Another highlight was managing to stick to the tight schedule. This was all thanks to the best possible preparation and well-structured planning with ongoing operations. “What’s more, we managed to increase picking output by around 50% on average, and, thanks to the lift system, saved 110 m² of 180 m² warehouse space, which can now be put to other use.” The machine building firm is now much less reliant on staff availability, as all six warehouse lifts can be easily operated simultaneously by one person. Following this project, WFL has already made further process optimisations, including tool stations on the lifts and a label printer with central printing station. To top it all off, only one shift operation rather than two-shift operation is now required to achieve the required performance levels. The plan for 2023 includes improvements to the goods-inward processes and the dispatch of spare parts. Should the range of small parts continue to grow out of proportion, the number of SSI LOGIMAT® warehouse lifts can be increased accordingly. There would definitely be enough space!