Multishuttle system for distribution center
Safe handling of 90,000 containers
Intralogistics specialist Dematic is automating the new distribution center of hard metal producer Ceratizit in Kempten in the Allgäu region. A seven-aisle Dematic Multishuttle system with around 90,000 container storage locations is being installed for this purpose, which enables space-saving, multi-deep storage.
In the storage system, 217 shuttles automatically access the bins and transport them directly to the high-performance picking stations. As a result, the system achieves a throughput rate of up to 570 containers per hour and workstation, enabling Ceratizit to increase the efficiency of order picking. 26 work stations for packing the goods and 24 for incoming and outgoing goods complete the system. These are connected to the storage system via conveyor lines with a total length of 1.7 kilometers.
"The Dematic Multishuttle system fits Ceratizit's requirements perfectly thanks to its high degree of automation and compact design," says Jessica Heinz, Head of Marketing and Business Development Dematic Central Europe. "It also ensures reliable and efficient order processing with a high throughput rate and error-free picking." The system takes up around 3,000 square meters of floor space, including the workstations, in the carbide manufacturer's new distribution center. Thanks to the direct connection of the rack aisles to the picking stations and the inter-aisle transfer patented by Dematic, there is no need for a conveyor loop in the pre-zone. The technology ensures that the containers can be moved across all aisles within the racking. In this way, the picking stations can flexibly access goods from all aisles. It also increases the system's reliability.
The containers in the Multishuttle measure 400x300 millimetres or 600x400 millimetres, whereby the latter can be divided into up to eight compartments. They are separated using cardboard inserts, which are identified by a unique barcode. An integrated, fully automatic camera system in the incoming goods area automatically records the exact position of the goods after the manual insertion of the inserts, without the employee having to scan the containers and inserts and enter the data manually via a dialog. This increases stock quality and processing speed in the incoming goods department, ensuring that products are available to customers quickly and reliably.
When an order is received, the shuttles transport the required items automatically and in the correct order to one of the seven high-performance picking stations. There, the Ceratizit employees compile the orders. They are supported by an SAP EWM (Extended Warehouse Management) dialog, which displays the relevant data for processing. There are also five stations specifically for picking semi-finished products. The intralogistics specialist equips all picking stations with a pick-by-light function, which visually highlights the item to be picked in addition to the graphic information on the monitor directly at the picking compartment. Dematic also integrates scales for weight control and handle monitoring when picking items. "This reduces the picking error rate to zero," says Heinz.
Dematic is installing SAP EWM software to control the system and the entire material flow. Standardized Siemens S7 controllers, which control the conveyor technology and the shuttle system, are connected to SAP via the new so-called ABAP Push Channel technology. This means that the corresponding control commands are exchanged directly between the SAP server and the S7 controller. Previously, this required an SAP PCo computer or the Dematic SubDriver, which can now be dispensed with. In this way, both the exchange of information and the smooth flow of materials are guaranteed. "We tailored the solution specifically to Ceratizit's requirements," says Heinz. User guidance is provided via modern UI5 dialogs, which clearly display all the necessary order data to the employee. The SAP EWM solution also manages and controls the manually operated warehouse and the Value Added Services area.
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