multi-temperature dc – all skus under one roof witron ... · • opm is used within the dry goods...

WHITE PAPER WITRON Integrated Logistics 3721 Ventura Drive, Arlington Heights, IL 60004 Phone: 847-385-6000 www.WITRON.com

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Multi-Temperature DC – All SKUs under one Roof

WITRON solution for entire SKU assortment and all temperature ranges EDEKA, Germany’s largest supermarket corporation has selected WITRON as the general

contractor for its latest distribution center. WITRON's solutions will be used in the new 520,000

square foot logistics center located in Berbersdorf, Germany. The plant will supply 520 EDEKA

stores with more than 12,000 products from departments such as dry grocery, perishable

goods, gourmet foods, meat, fruits, vegetables, and frozen goods. The Ramp-up is organized

in multiple steps and will start in summer 2014. The system will be completed by the first

quarter of 2015.

All in all there are six innovative Witron systems integrated into this DC which will be described

in the following article.

WITRON's Order Picking Machinery - OPM (dry goods assortment), Dynamic Picking System -

DPS (dry goods assortment / meat), Ergonomic Tray Picking ETP (gourmet food / frozen

goods), and Car Picking System - CPS (gourmet food / fruits + vegetables) solutions will enable

EDEKA to pick up to 378,000 cases onto pallets, roll containers, insulated containers, or totes.

WITRON’s software enables all cases to be picked in a “store friendly” manner. This means that

all products are arranged to be easy to unpack from the different containers. Consequently the

walking distance, lifting efforts and time used to unpack are reduced significantly for the EDEKA


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employees at each store. Additionally WITRON’s software takes the layout of each of the 520

stores into account for every order. All workplaces in the material flow process were designed

according to the latest ergonomic standards. Based on the implemented WITRON technology,

all processes within the entire supply chain of the logistics center will be logically and physically

integrated. This includes not only the actual storage and picking, but also processes like

receiving, replenishment, empty pallet handling, and shipping. The results for EDEKA are high

transparency, low error rates, and optimization of service and logistics costs. For example, the

management of empty pallets, roll containers, and insulated containers is integrated into the

receiving process from a conveyor system point of view - starting with receipt and withdrawal, to

the timed re-provision in the respective picking area - efficiently controlled by means of a

mechanized empties buffer. Following the storage and picking process, an automated dispatch

buffer will organize and optimize the entire shipping process. The dispatch buffer is divided into

different temperature zones. It stores and sorts order pallets, roll containers, and insulated

containers, and transports those in a consolidated manner and in mixed mode via dispatch

lanes to the dispatch gates. This is done using the shortest route, sequence-friendly, and just-

in-time.

The implemented logistics systems

OPM - Order Picking Machinery Fully-automated case picking for food retail

Since its market launch in 2003, the patented, award-winning storage and picking system OPM

has become the world's most successful automated case storage and picking system in food

retail.

The OPM is able to automatically stack 95% of the entire article spectrum of a typical grocery

retailer onto pallets or roll containers in a store-friendly manner. The heart of the system is the

Case Order Machine (COM), which is capable of picking cases automatically onto pallets and

roll containers. - The system output amounts to more than 500 picks per hour. The OPM

handles dry goods, the fresh food area, and the frozen goods sector.

The OPM technology generates significant advantages along the entire supply chain. Not only

are there benefits within the distribution center itself (high cost-efficiency and ergonomics), the

system also optimizes transportation (up to 20% more densely packed pallets or roll

containers), and offers synergies in the supermarket (store-friendly picking).


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Due to the modularity and flexibility of the system, it is possible to use this technology cost-

efficiently for almost all warehouse sizes without any problems - no matter if the distribution

center handles 13,000 cases per day or more than 600,000 cases per day - no matter if the

product range consists of 300 articles or 18,000 articles.

The long-standing experiences from the projects realized so far show that the use of OPM

generates a great multitude of advantages for the operator. Sustainable competitive

advantages and differentiation characteristics in terms of product availability and store service in

the supermarket, as well as increased cost-effectiveness and efficiency within the entire supply

chain are only a few of them. Based on its ergonomic work processes, an extremely space- and

energy-efficient technology, and the optimal trailer load, the OPM is also pioneering in terms of

sustainability.

Characteristics

• Automation of all processes from receiving to shipping

• Fully-automated order picking by the Case Order Machine "COM" • Maximum availability through the use of trays

• Fully-automated picking of different cases

• OPM is used within the dry goods assortment as well as in perishable and frozen

environments

• No need for personnel within the entire material flow process

• Picking onto either pallet or roll container

• Store-friendly picking according to the store layout

Successful OPM technology. More than 500 COM machines are currently in use or in the realization phase

worldwide.


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DPS (Dynamic Picking System) Highly dynamic picking of small parts by means of pick-by-light

The highly dynamic and automated picking of small parts in DPS is supported by a pick-by-light

system. DPS works according to the goods-to-person and person-to-goods principles.

Depending on the order structure, the articles are provided permanently or on demand in the

pick front, enabling continuous optimization.

DPS enables the direct storage and picking in an automated small parts warehouse (AS/RS).

The replenishment of the picking zones integrated in the tote warehouse is exclusively system-

controlled using stacker cranes within the AS/RS. The classification of the article structure is

permanently verified and adapted by DPS.

Based on the static and dynamic provision of the stored goods, the walking distances for each

picker are reduced by up to 75%. Integrated ergonomics plays an important role for all

workstations – beginning at the repacking workstations where the goods are put into totes

through to the workstations for the order picking. The lifting and carrying of totes in the DPS is

reduced to a minimum.

DPS supports different types of order picking: From tote into tote, from pallet into tote, from tote

into shipping carton, etc.

Characteristics

• Picking principle: Combination of goods-to-person and person-to-goods

• Integrated storage and picking in one automated system

• Automated replenishment of the pick front by stacker cranes

• Permanent provision of fast movers in static SKU channels. Demand-tailored provision

of slow movers in dynamic SKU channels

• Compact pick front and reduction of the walking distance by up to 75%

• ABC-friendly article provision in the pick front

• Picking from triple-deep flow channels

• Use of pick-by-light technology and terminal visualization system

• Footprint savings of up to 50% compared to conventional storage


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In DPS, walking distances are reduced by up to 75%

ETP (Ergonomic Tray Picking) Ergonomic case picking supported by pick-to-light

ETP is a semi-automated person-to-goods solution designed for case picking. The ETP concept

is ideal for distribution centers within food retail, for regional, fast-mover warehouses, for full-

range providers, and discount retailers. It can be used in both ambient and cooled

environments. In terms of mechanization, the ETP solution impresses by its ideal combination

of fully-automated replenishment and ergonomic order picking. Cases are picked from a tray

mini load pick front onto pallets or roll containers using specially designed “person-aboard”

cranes.

Every single order is picked according to specific requirements, family-grouped, and based on

the respective store layout. The stacking algorithm corresponds exactly to the algorithm used in

WITRON's mechanized OPM system. Based on this key functionality, users benefit from many

years of field-proven experience with OPM.

For each pick, the operator cabin is automatically positioned such that the picker doesn’t need

to lift, carry, or bend in order to perform his or her pick. The key optical tool is a beamer

mounted on the vehicle. This shows the operator, where, and in what position, he or she should

place the case on the order pallet or roll container. Thanks to this pick-to-light support, the pick

efficiency during the case picking process is considerably increased and the store is provided

with an aisle-friendly pallet or roll container.

ETP is able to reach a very high pick performance compared to conventional warehouse

systems, independent of the age or gender of the picker. ETP is not only suitable for new

logistics centers, but it can also be implemented into existing buildings and systems without


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special efforts and during running operation. Therefore, ETP is also a possible solution for

modernization projects.

Characteristics

• Picking principle: Person-to-goods

• Designed to handle an article range of up to 4,000 different items

• All articles for this assortment are provided in one aisle. No need to sequence the order

pallet

• All module aisles work independently from each other - order will be completed in one

aisle

• Picking with highly ergonomic, IT-controlled pick shuttles - no lifting, no carrying, no

bending, no foil removal

• Shortening of the pick front to 1/20 of a conventional warehouse

• Stacker cranes supply the pick front and remove empty trays

• Store-friendly picking onto pallet or roll container based on an IT-generated stacking

algorithm

• Visualizing the storage position of the picked case on the load carrier by means of

beamer and screen (repeated display of the storage position, the removal quantity, and

product image)

The ETP, ensures the picking process is completely ergonomic.


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CPS (Car Picking System)

The CPS storage system is a manual order picking system for route-optimized picking of cases

onto pallets or roll containers, supported by radio frequency, (RF), pick-by-voice, or pick-by-light

technology. The order-related replenishment of the pick front is automated through the use of

stacker cranes. The positioning of an article is performed in a store-friendly picking process.

According to the principle "person-to-goods" it is possible in CPS to pick several orders in

parallel by one picker.

Characteristics

• Picking principle: Person-to-goods

• Automatic, order-dependent replenishment by means of stacker cranes

o we don’t offer this is practice!Fast movers: static pick locations

• Pick front integrated within an automated pallet warehouse

• Use of person-aboard pick mobiles

• Route-optimized picking

• Manual picking of cases onto pallet or roll container supported by radio frequency, pick-by-voice,

or pick-by-light technology, as well as terminal visualization system

• Possible to pick several orders at the same time

In CPS, order picking is done manually. Replenishment of the pick locations is automated


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Mechanized empties buffer The fully innovative mechanized empties buffer, with technology developed by WITRON and manufactured by its subsidiary FAS, is a solution that guarantees a cost-effective and efficient empties handling in the material flow. In this newly developed technology, pallets, and insulated containers are supplied directly by the truck driver or a warehouse operator into the logistics system when returned to the distribution center. This is done via loading points and supported by conveyor system. It is possible to directly load several load carriers of different types per conveying distance at the same time. Based on the patented technology, these load carriers can be transported on the same conveyor line and in mixed mode. Dirty load carriers can be cleaned through the integration of a washing machine. Afterwards, the different load carriers are stored into the buffer through stacker cranes, removed on demand, and supplied to the respective pick zones. If the empties are required immediately in the system, there is no immediate intermediate buffering. If more empties are required for picking than supplied, the demand is compensated by the buffer.

Characteristics • Optimal empties management: A lack of supply can be eliminated. This results in an

optimum empties management not only on peak days, but also on days with low throughput.

• Cost-efficiency: Based on the mechanization of the empties process, warehouse personnel can be used for more effective tasks. The cost-efficiency of the entire empties process is increased considerably.

• Reduction of construction costs: The optimal use of the entire building height through the integration of rack systems results in savings of building footprint and consequently to a reduction of construction costs.

• Different empties types: The empties buffer enables the intermediate buffering of Euro pallets and other different empties types like roll containers and insulated containers in one system.

• Maintaining quality: Outdoor storage is eliminated, thus ensuring that the quality of the different load carriers is maintained. Moreover, the mechanized buffering guarantees protection against damage and theft of the load carriers.

• Cleanliness: An empties washing machine can be integrated into the system.

• Safety: Based on the completely mechanized transport, forklift traffic is reduced considerably. With the elimination of complex buffer zones, the safety in the warehouse is generally increased, and sources of errors are minimized especially since empty pallet stacks do no longer block the view


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Mechanized shipping buffer With this completely new and mechanized shipping concept, WITRON has developed an

innovative solution that significantly improves the material flow processes within the shipping

area as well as trailer loading.

IT-controlled and just-in-time for dispatch, all load carriers - sorted according to routes or even

to store and in the optimal trailer loading sequence - are provided on the dispatch lanes for the

loader.

But the shipping buffer has even more benefits. For example, the individual modules can be

divided into different temperature ranges. Different products like dry goods, fresh products, dairy

products, fruits, or vegetables, and even frozen goods can be stored without any problems in

the same shipping buffer. Separate outbound areas for every temperature zone - leading to a

greater overall warehouse footprint.

An optional software module developed by WITRON carries out an exact trailer filling

calculation for every outbound trailer type and size.

Besides the logistical benefits, WITRON's energy-efficient technologies and processes have a

positive impact on the transportation costs and gasoline usage. . Densely packed load carriers,

picked on the basis of proven stacking algorithms, in combination with a highly effective

dispatch process, ensure an optimum trailer load, maximize the trailer utilization, improve the

efficiency of the route, and make a significant contribution to environmental protection.

Characteristics

• High cost-efficiency due to footprint savings

• High cost-efficiency due to reduced trailer dock time based on faster trailer loading

processes

• High cost-efficiency due to savings of personnel based on an effective dispatch handling

• Reduced number of forklifts

• Parallel and automatic buffering and dispatch provision of Euro pallets and roll containers

in one system due to modular design and patented technology - independent of article

spectrum or temperature zone


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• Sequenced provision of dispatch units - optimized and IT-controlled for every tour or

store, sequenced based on loading sequence and "just-in-time" for shipping

• High dynamics due to short distances between the shipping buffer and the dispatch dock

• Decoupling of picking and shipping with the automated buffer allows continuous operation

of the fully-automated picking system - 24 hours a day - and at the same time, an efficient

and demand-related use of operators during loading times. Thanks to the transparent

storage of picked customer orders in the shipping buffer, picking is also possible in

phases with no loading activities without the shipping area being overfilled.

• 100% loading control, as the load carriers leave the shipping buffer in the right sequence

directly via the dispatch lanes towards the person responsible for loading

The automated WITRON shipping buffer stores both Euro pallets and roll containers before they

are shipped. The individual modules can be divided into different temperature zones at the

same time.


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Company profile WITRON Integrated Logistics Foundation: 1971

CEO: Helmut Prieschenk

Employees: 1,750 (end 2012)

Revenue: 320 million USD (end 2012)

WITRON designs and implements innovative logistics and material flow systems with trend-

setting ergonomic work places and processes that offers their customers sustainable

competitive advantages. WITRON has the key elements for a successful project under one roof:

logistics design information and control technology, mechanics design and mechanical

production, as well as the responsibility to act as a general contractor. WITRON's experience of

more than 2,000 implemented logistics projects is leveraged in the conceptual stages of system

design. WITRON builds customer loyalty by offering individual service and operator models that

exactly match the requirements of their customers. Moreover, a comprehensive coverage of the

entire project cycle is the best way to continuously develop existing logistics modules and

innovate according to the market needs.

For many years the top companies throughout Europe and North America have been operating

their distribution centers efficiently and successfully with WITRON's solutions. The fact that 80%

of WITRON's customers are returning customers - this means customers that have already

operate a WITRON system - shows the extent of customer satisfaction.

The WITRON scope of supply

- Logistics design

- General contractor

- Software & control engineering

- Mechanics production

- Service & maintenance

- System operation

- Modernizations / retrofits


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Subsidiaries:

Parkstein, Germany (headquarters), Arlington Heights, IL (USA), Toronto (Canada), Stoke-on-

Trent (UK), Madrid (Spain), Strassburg (France), Venray (The Netherlands)

The WITRON headquarters in Parkstein (Germany)

The WITRON headquarters in Arlington Heights, IL

Contact data:

WITRON Integrated Logistics Corporation 3721 Ventura Drive USA-Arlington Heights IL 60004 Phone: 001 847 385 6000 Fax: 001 847 398 6140 [email protected]


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Company profile EDEKA Group

The EDEKA Group is the largest food retailer in Germany. The Group's dynamics are decisively

shaped by the 4,000 self-employed EDEKA retailers. With some 317,600 employees and

18,200 trainees, the EDEKA Group generated revenue of 45 billion Euros in the fiscal year

2012. The distribution network of the Group comprised a total of 11,684 food retail outlets by the

end of 2012. Besides the full-range business operated by independent retailers, Netto, the third

largest food retail discounter across Germany, is also part of the EDEKA Group.

Company logo EDEKA Group

http://www.handelsdaten.de/statistik/daten/studie/254600/umfrage/umsatz-der-fuehrenden-unternehmen-im-lebensmittelhandel-in-deutschland-2012/

http://www.handelsdaten.de/statistik/daten/studie/210882/umfrage/edeka-gruppe-zahl-der-mitarbeiter-in-deutschland-zeitreihe/

http://www.handelsdaten.de/statistik/daten/studie/211450/umfrage/edeka-gruppe-zahl-der-auszubildenden-in-deutschland-zeitreihe/

http://www.handelsdaten.de/statistik/daten/studie/210877/umfrage/edeka-gruppe---umsatz-in-deutschland-zeitreihe/

http://www.handelsdaten.de/statistik/daten/studie/210877/umfrage/edeka-gruppe---umsatz-in-deutschland-zeitreihe/

http://www.handelsdaten.de/statistik/daten/studie/210880/umfrage/zahl-der-verkaufsstellen-von-edeka-in-deutschland-zeitreihe/

http://www.handelsdaten.de/statistik/daten/studie/210880/umfrage/zahl-der-verkaufsstellen-von-edeka-in-deutschland-zeitreihe/

http://www.handelsdaten.de/statistik/daten/studie/236598/umfrage/umsatz-der-fuehrenden-lebensmittel-discounter-in-deutschland-2011/

multi-temperature dc – all skus under one roof witron ... · • opm is used within the dry goods...

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