Stocksaver ensures transparency of stocks in the FIFO shelves at Auto-Kabel, protects against empty runs and reduces safety stocks to a minimum.

Stocksaver is maintenance-free, easy to retrofit and suitable for all FIFO roller shelves. The reporting points in the rack ensure transparency of the material stock and protect against incorrect deliveries or empty runs thanks to automated material requests. The aim is to halve the stock on the shelf, as previously necessary safety stock can be reduced. Sensors monitor the actual material stock as a reporting point in the logistics chain. A so-called smart box transmits this data to the Stocksaver software via a wireless network. This ensures transparency at all times regarding the material available at the workplace. The system solves all typical Kanban problems, creates more space in production and increases cash flow. The automatic material request largely eliminates human error, making safety stocks superfluous.

Automation avoids human error

"A major advantage of Stocksaver is that the sensors fit all containers and all roller shelves," explains Manuel Schutzbach, who works in Technical Sales at Werma. "If a container removal triggers the reorder level, the requirements list is automatically updated." The system also eliminates manual sources of error such as forgotten or lost Kanban cards or missing empty reports. As scanning processes are no longer necessary when picking and there are no more double bookings, the system offers far-reaching resistance to errors.

The data is transmitted wirelessly and displayed in the supplied software. "Commissioning the hardware and software was very intuitive, so no external project or consultancy costs were incurred," says Alisa Schwald, Co-Project Manager Industrial Engineering. The software displays the material stocks of the integrated roller shelves on the PC.

The control station provides an overview of the material stock at each workstation. The requirements list informs logistics in good time about replenishment requirements and priorities. The software also provides evaluations that can be used to analyze and optimize processes.

Improvements were already apparent after the first test run with the three roller shelves. "We were able to immediately reduce our downtimes and safety stocks. This project paid for itself within just six weeks," says Schwald with satisfaction. In addition, the machine operator no longer has to leave his workstation to order replenishments. The control station view shows the shelf view including the material number, the storage location, the priority for replenishment and the number of replenishment containers required. In addition, evaluations and the option to export data help to improve processes in the long term.

Additional safety through light signals

"After the first test runs, we had one more request for improvement," says project manager Engelhardt: "To ensure even greater safety, eliminate any risk of confusion and simplify the logistics operator's work, we wanted to install additional "place-by-light" lights on the shelves. These should clearly indicate in which shelf compartment the delivered material is to be placed. We were very pleased that Werma realized this wish for us and will now also offer it to other customers." After the scanning process, the system gives a green signal to indicate to the logistician in which shelf compartment the material can be placed. If it has been placed in the wrong compartment, the light turns red. "It is now virtually impossible to mix up the shelf compartment," says Engelhardt.

"We were particularly impressed by the fact that Werma is using the system itself and has been testing it in its own production facilities right from the start," says Schwald. "We were also impressed by the advice and personal contact." When asked how the new system is being accepted and used by the employees, Maik Engelhardt replies: "Everyone involved is now convinced of its functionality - from the team leader to the machine operator."

Thanks to the good results and the short amortization period, Industrial Engineering already sees further potential applications at Auto-Kabel: "At our next lean workshop, we will present Stocksaver at the other locations. This is where we regularly present the most successful projects from all plants, and we will recommend rolling out the system to all branches with similar requirements." am