In the future, orders were to be processed more efficiently with the same number of employees, which necessitated a reversal of the picking processes to the goods-to-person principle.

In cooperation with Dematic in Germany, a space-saving storage solution was developed that could be seamlessly integrated into the existing building. The solution includes a multishuttle system featuring multiple deep storage with 5,760 storage locations as well as a tote conveyor system.

Within the multishuttle system, 12 shuttle vehicles take over the order sequence formation. The conveyor technology transports the requested articles to the various workstations. Thus, the intralogistics solution has completely automated the previously manual storage and retrieval as well as order picking of the goods and the entire material flow.

“The Dematic Multishuttle significantly increases speed, storage density, accuracy and availability within the picking warehouse. In addition, the overall system enables high throughput rates as well as error-free picking, thus guaranteeing us efficient and reliable order processing.”
Boris Herrmann, Process Manager, Schmidt Groupe S.A.S.

Picking process flow

Order compilation first begins at the small parts workstations, where the employees use a pick-by-light system to individually load cartons with the requested items.

Depending on the volume of the items, they are optimally delivered to three workstations so that the employees can always work with similarly large order volumes. Screws are picked first, then the A-class items and finally all other items. Next, the boxes are transported to the subsequent stations with special roller and belt conveyors. If larger items need to be added to an order, the small parts carton is loaded onto a tray and stored or buffered in the Dematic Multishuttle warehouse.

The multishuttle solution offers space for 5,760 storage locations on 12 levels. On each level, shuttles take over the automatic order sequencing as well as the storage, transfer, and retrieval within the multishuttle system.

The filled containers and trays are transported to the other workstations via the conveyor system. During this process, a continuous scale monitors the weight. As soon as the order is complete, the sequenced totes are checked, the cartons are sealed and shipping labels are applied. In addition, the system has capacity to accommodate future growth.