Warehouse management system digitizes production logistics

Ehrle, a provider of vehicle washing and cleaning technology solutions, has set up a new production facility designed according to lean manufacturing principles. When designing the new production processes, the focus was on coordinating production with intralogistics. In addition, warehouse management across several locations in Germany and abroad was to be optimized through the introduction of a central system.

Reply supported Ehrle in redefining the processes in the warehouse and production and implemented the Click Reply WM warehouse management system. This not only allows the management of several warehouses at locations worldwide, but the system also takes on a central role in production thanks to specific extensions.

Extended sequencing functionality
The connection between Click Reply WM and the ERP system creates integrated production: the WMS learns from the ERP which orders are pending. Using a sequencing functionality developed by Reply, Click Reply WMS calculates which parts and components are required at which time on the five central production lines and in the 14 assembly departments. The WMS knows the location coordinates of the components in the warehouse and in the Kardex shuttle systems and also knows whether a part is in the front or rear position within the PushBack racks used. Click Reply uses this information to calculate the routes of the semi-automatic stacker in order to optimize the guided picking for production and avoid empty runs of the stacker.

The integration of human employees is crucial for smooth production processes. © (Image: Ehrle GmbH)

The data from the WMS controls the semi-automatic stacker and ensures that the required parts are available "just in sequence" at the respective production location.

Transparency through Andon displays
Efficient production requires more than just high-performance systems: The integration of human employees is crucial for smooth production processes. Reply installed Andon displays in the production area as an interface between intelligent systems and human employees. These monitors inform the employees via a dashboard that was specially developed by Reply for Ehrle. This makes Click Reply WM a central component of modern and efficient production.