Dematic have announced that Ferdinand Gross, a supplier of fasteners and connectivity technologies, have installed a customised storage and order fulfilment solution featuring the new Dematic Multishuttle automated storage and retrieval systems.
Dematic Multishuttle is an Automated Storage and Retrieval Systems (AS/RS) solution for applications that require high rate, product sequencing to support order assembly, goods to the person picking, and pick face replenishment.
Dematic Multishuttle automated storage and retrieval systems have the following features:
- Higher rate capacity
- Ability to accommodate load sequencing requirements
- Adaptability to existing building layouts
With the Multishuttle automated storage and retrieval systems, Ferdinand Gross can reduce order throughput times and can extend the incoming order cut-off time.
For customers, these changes mean improved services. At a delivery deadline established by the customer, all pending orders in the system are bundled into a single shipment. The resultant later order dispatch window allows better bundling of individual orders, thereby reducing the number of packages to be consigned.
The Multishuttle automated storage and retrieval systems at Ferdinand Gross have higher dynamic picking. The systems feature two Multishuttle versions, ‘Captive’ and ‘Roaming’ in a single storage unit with identical shuttles in both areas.
The Multishuttle roaming system is designed for the fast moving items, improving availability and flexibility. In the roaming area, 20 shuttles serve the 59,000 storage positions at a throughput rate of 615 double cycles (parallel storages and retrievals) per hour. Every aisle contains one shuttle which accesses each level by lift and then runs on the rail to the selected storage position. The individual shuttles are transferred between levels through lifts at good speeds.
The Multishuttle captive area manages order picking of items from the roaming section, shelf storage system and picking-related logistics. Each level in the aisle is equipped with its own shuttle. The shuttles retrieve tote boxes from storage positions and convey them to a lift at the end of the lane.
The lift vertically transfers the boxes to the out-feed conveyors, which lead to an ergonomically-optimised picking station. Sequencing to customer specification is possible, i.e. delivery of goods from inventory in the precise sequence that they are needed for picking of the order. In the captive area, 12 shuttles are operational, serving 5000 storage positions at a rate of 514 double cycles per hour. With the Multishuttle automated storage and retrieval systems, Ferdinand Gross have achieved the following:
- Expansion of storage capacity by 60,000 positions to 55,000 in roaming system and 5000 in captive system
- Improvement in order fulfilment times, extending order acceptance deadlines
- Improvement of service performance as a result of the additional captive lane
- Sequencing to customer specification and individual labelling
- Manual access to storage positions in the Multishuttle automated storage and retrieval systems
- Higher redundancy as items can be processed at any location and the workstations are decoupled
- One employee processes the entire order (improved traceability)
- Ergonomic workstations for improved operator performance and safety
- Modular concept, allowing for future expansion at any time
Ferdinand Gross’ customers utilising Kanban have benefited with the Dematic Multishuttle automated storage and retrieval systems as order fulfilment times were shortened from an average of one week to a single day.
Previously, customers’ shipping containers had a fixed label, showing article number, article description, amount, and customer name. Once the customer emptied the container, Ferdinand Gross would pick it up and return it to the DC, ready to be refilled and shipped out again. With the new system, customer containers can now be relabelled for filling with any product rather than waiting for the original empty container to return to trigger the order. Consequently, return trips with empty boxes can now be bundled, reducing the number of trips to and from the customer. This cuts transport costs and has a positive impact on the environment.
Following is the summary of logistics data and facts:
- Total of 120,000 shelf storage locations, 20,000 pallet storage spaces at parent company in Leinfelden-Echterdingen, Germany
- 72,000 standard parts, 24,000 customer specific parts, 11,000 tools permanently in stock
- 5000 order lines per day in the forwarding department
- Approximately 40 tonnes each of incoming and outgoing goods each day
- Handling capacity of over 1000 picks per hour
- New bin warehouse: shelf height of 12m with 30 levels, shelf length of 31m and shelf width of 19m
- Multishuttle roaming: 5 lanes with 20 Shuttles, 615 double cycles/hour
- Multishuttle captive: upper 12 levels per lane, 12 shuttles, 514 double cycles/per hour