References

Adolf Würth GmbH & Co. KG

Logo Würth
  • Branch
    Industry
  • Location
    Künzelsau, Germany
  • Solution
    Efficient and ergonomic one-touch handling
  • Core technologies
    OSR Shuttle™, Pick-it-Easy work stations
  • Picking performance
    4,500 order lines/hour

The Würth Group has 400 companies in more than 80 countries with over 63,000 employees. The article range includes over 100,000 items such as screws, plugs, tools, fittings for furniture as well as construction and industrial safety products.

In the most modern, high-performance distribution centre of the Würth Group, around 60,000 order positions are processed daily, and most of the items in the range are heavy. All warehouse processes are decoupled from each other, thanks to the combination of a dynamic workload control system and the use of a buffer. This guarantees maximum flexibility between automation, the use of resources in manual, semi-automatic and fully-automatic stations, and departure times – resulting in a highly-flexible, end-to-end system. Moreover, the goal was a system with one-touch-handling. Each item that leaves the logistics centre is touched only one time during processing.

The ergonomic Pick-it-Easy work stations are designed according to the latest occupational health information and make it possible to pick even heavy parts ergonomically. Special start and route algorithms coordinate all of the processes within the warehouse. Four fully-automatic pallet cells complete the dispatch process where cartons are stacked on a goods-out pallet based on optimal packing patterns.

ALOG | tmall.com

Logo ALOG
  • Branch
    Food Retail
  • Location
    Guangzhou, China
  • Solution
    E-Grocer
  • Core technologies
    Streamline conveyor system, dispatch sorter
  • Daily performance
    54,000 orders from 640,000 articles

ALOG, the leading subsidiary of the Alibaba Group in China, offers high-quality logistic services for tmall.com, the Alibaba online grocery portal. Their online ordering needed to be efficiently organized. KNAPP therefore designed a conveyor-supported, manual solution with a dispatch sorter.

Fast and medium movers are picked from a flow rack. Slow-movers are picked in batches from static racks. The powerful Streamline conveyors reduce walking time within the warehouse and bring efficiency to the picking process. A high-speed sorter automatically sorts the completed orders. Each hour, 6,500 orders can leave the warehouse, sorted according to post code.

 

Apologistics

Logo Apologistics
  • Branch
    Healthcare
  • Location
    Markkleeberg bei Leipzig, Germany
  • Solution
    E-commerce for pharmacy and pharmaceutical wholesale
  • Core technologies
    Central Belt System with KNAPP-Store
  • Deliveries per day
    Around 8,000

Apologistics is moving into a new sector in pharmaceutical retail – e-commerce. Through the online portal, apodiscounter.de, customers can order their medicines online and receive them comfortably at home within 24 hours.

Apologistics turned to the new KNAPP-Store to automate goods-in for slow movers, to handle returns and to efficiently store a broad range of articles.

The KNAPP-Store fulfils the requirements that Apologistics had for performance and storage density, and significantly increased the degree of automation and efficiency of the warehouse. In the e-commerce business, which is influenced by a large number of small-quantity orders, the advantages of the KNAPP-Store are especially effective in comparison to manual picking, because it can process orders faster, with less effort and no errors.

AuchanDirect

Logo Auchan
  • Branch
    Food Retail
  • Location
    Paris, France
  • Solution
    E-Grocer
  • Core technologies
    OSR Shuttle™, Pick-it-Easy Health work stations
  • Daily performance
    160,000 single items and 2,800 orders

AuchanDirect.fr is the online portal of the French grocery chain Auchan. Customers from the regions of Paris, Lyon, Marseilles and Lille can order from AuchanDirect.fr and have their shopping conveniently delivered to their home within 24 hours.

The heart of the distribution centre is the storage and picking system OSR Shuttle™ with 13 rack line systems and 48,000 storage locations. It supplies 13 connected ergonomic Pick-it-Easy Health work stations for goods-to-person picking. The OSR Shuttle™ also serves as a dispatch buffer – the system retrieves containers in the correct sequence for order fulfilment and conveys them to two stacking machines. These in turn automatically load the roll containers, processing 2,400 containers per hour.

Basiq Dental

  • Branch
    Healthcare
  • Location:
    Oisterwijk, Netherlands
  • Solution:
    Robot Picking
  • Core technologies:
    Pick-it-Easy Health, Pick-it-Easy Robot, OSR Shuttle

Basiq Dental, based in the Netherlands, supplies dentists in large parts of Europe with its comprehensive range of high-quality dental equipment. As a customer-orientated company, Basiq Dental always strives to better provide for its customers through innovative services, and is always a step ahead of the competition. In KNAPP, Basiq Dental has found a partner who supports them on their path to success with innovative and high-performance automation technology. KNAPP equipped the Oisterwijk distribution centre with a combination of tried-and-tested shuttle technology and brand-new robot technology.

Basiq Dental is breaking new ground in intralogistics with the innovative Pick-it-Easy Robot picking robot, as well as investing in a reliable, high-performance and economical picking system. A key element of the Basiq Dental automation solution is the combination of OSR Shuttle™, Pick-it-Easy Health and Pick-it-Easy Robot. Being able to use divided containers provides especially high storage density in the OSR Shuttle™ and makes maximum use of the available space. The special design of the Pick-it-Easy Health work station allows efficient and error-free goods-to-person handling with steady quality and performance, even over longer periods of time. Pick-it-Easy Health therefore brings performance, reliability, precision and ergonomics to the manual work processes, contributing to quality and the efficient use of resources within the warehouse. What’s more, robotic picking with the Pick-it-Easy Robot increases both performance and delivery quality, and reduces costs in the face of increasing numbers of orders.

Boots UK

Logo Boots
  • Branch
    Retail
  • Location
    Burton-upon-Trent, UK
  • Solution
    Omni-channel retail
  • Core technologies
    OSR Shuttle™, Pick-it-Easy work stations, KiSoft WMS

Boots UK is the leading commercial enterprise for health and beauty articles in the UK. The online business is characterized by a huge stock of goods for small orders consisting of different products as well as extremely high seasonal peaks.

The balanced interaction of manual and automated processes handles orders much more efficiently. In addition, the Burton Centre has sufficient flexibility and capacity to smooth over peaks in demand. With the innovative KNAPP solutions, Boots UK is in the position to develop the services for its customers even further and is equipped for the future growth of the boots.com business.

Brax

  • Branch
    Fashion
  • Location:
    Herford, Germany
  • Solution:
    Secure identification and extremely high transport and sorting performance of clothes
  • Core technology:
    roller adapter system
  • Matrix sorter performance:
    up to 6,000 items/h

BRAX, the clothing specialist from Herford, supplies 60 countries with high-quality clothing – to build the new logistics system, BRAX relied on the know-how of Dürkopp Fördertechnik, a member of the KNAPP Group.

For storage a barcode scanner reads the label on the pair of trousers and allocates them to a roller adapter. Each pair of trousers can be traced throughout the entire system. The warehouse system comprises 3 levels holding 200,000 articles – each level has more than 32 stand-alone modules. A vertical, reversible platform-elevator transports each pair of trousers to its assigned level.

The trousers are divided into sorting runs and transferred to one of 30 batch buffer lines. A three step matrix sorter creates an arbitrary sequence of trousers and by decoupling the three sorting steps, the matrix sorter reaches a speed of about 6,000 items per hour. The matrix sorter is an optimal solution in terms of space requirements and costs.

For dispatch the trousers arrive in the multifunctional goods-out buffer, where, for example, value added services can also be carried out. The trousers finally arrive at the packing area, comprised of 20 packing work stations. The trousers are decoupled from the roller adapters and packed for shipping.

Celio

Logo Celio
  • Branch
    Fashion
  • Location
  • Solution
    Shop-friendly delivery
  • Core technologies
    OSR Shuttle™, split tray sorter, overhead conveyor
  • Articles per hour
    15,000

The French men’s fashion company has a network of more than 1,000 shops in France, Italy, Spain and Belgium. Celio is number one for men’s fashion in France and offers a wide range of clothing for business and leisure.

With this automation solution, 15,000 articles per hour can be picked; the service level was raised to 97 percent and the error rate reduced. The KNAPP mix of technologies optimized processes along the entire supply chain. The modular solution also easily adapts to changing order structures.

EDEKA Kempf

Logo EDEKA Kempf
  • Branch
    Food Retail
  • Location
    Heddesheim, Germany
  • Solution
    Reusables Management Solution
  • Core technologies
    Container, pallet and roller container conveyor systems, full-pallet detection, 5 electronic image recognition systems, automatic transfer shuttle, automatic palletizing robots, KiSoft RCS
  • Sorting performance
    12 million crates/year; 51,000 crates/day; 3,200 crates/hour

The EDEKA Kempf Heddesheim location provided KNAPP the opportunity to put its innovative empties sorting solution RMS (Reusables Management Solution) – a particularly efficient and resource-efficient empties management system – to good use. Proven technologies combined with future-oriented innovations were used.

The semi-automatic system offers the optimal degree of automation for each article and each process step. KiSoft RCS is used as the central software for managing crates. It is responsible for the complex material flow, the management of empties and the precise booking of goods by retailer. A modern electronic image recognition system is used to identify about 600 types of crates. Completing the system are the patented transfer shuttle, automatic palletizing robot as well as container, pallet and roll container conveyor systems for efficient transport. Above all, EDEKA Kempf profits from the high sorting performance and the increased level of service. Cost and labour intensive processes are more efficiently organized, reducing the unit costs.

EDEKA trinkgut

Logo EDEKA trikgut
  • Branch
    Food Retail
  • Location
    Hamm, Germany
  • Solution
    Reusables Management Solution (RMS)
  • Core technologies
    Pallet and container conveyor systems, electronic image and logo detection systems, automatic depalletizing and palletizing robots, single bottle sorting robots, automatic transfer shuttle, KiSoft RCS
  • Sorting performance
    25 million crates/year; 100,000 crates/day; 6,500 crates/hour

In Hamm, the reusables from about 400 EDEKA and trinkgut stores needed to be processed efficiently, so the sorting solution RMS was used. KNAPP achieved a system that automatically records and sorts returned beverage crates and bottles, supplying them to the beverage producers ready for shipping.

The sorting system is semi-automatic and provides end-to-end transparency for the flow of empties. KiSoft RCS is the central software managing 100,000 crates/day without using paper. It is responsible for the complex material flow, management of empties and the precise booking of goods by retailer. Electronic image recognition technologies identify 200 different types of bottles and 1,000 types of crates. The bottle-sorting robot assembles unmixed beverage crates. The patented transfer shuttle, the automatic depalletizing and palletizing robots and container and pallet conveyor systems complete the system.

ENGEL Austria

Logo Engel
  • Branch
    Industry
  • Location
    St. Valentin, Austria
  • Solution
    Automated production logistics with integrated SAP® EWM
  • Core technologies
    YLOG-Shuttle, SAP® EWM by KNAPP
  • SKU
    12,000 articles in the small parts warehouse

The Austrian company ENGEL Austria GmbH is a specialist and world market leader in the manufacture of injection moulding machines. ENGEL was searching for a new, integrated automation solution for their production location in St. Valentin, Austria and decided on a mix of technologies from the KNAPP Group – a YLOG-Shuttle System from KNAPP Industry Solutions in combination with an SAP®-EWM solution from KNAPP IT Solutions.

One of the main requirements ENGEL had was to implement an integrated warehouse management and material flow system (WMS/WCS) that would replace the control computer for the existing high-bay warehouse and seamlessly integrate the existing SAP® ERP features into the new software solution. Along with optimized control technology for the warehouse system, all work stations are equipped with intuitively operated easyUse user interfaces, which are also integrated in SAP® EWM. The easyUse user interfaces are individually adapted to the requirements and processes at ENGEL and efficiently guide the employee through the work processes without error. The easyUse interfaces facilitate intelligent man-and-machine communication and are in sync with the zero defect philosophy of KNAPP.

Estuario Carni

Logo Estuario Carini
  • Branch
    Food Retail
  • Location
    Noventa di Piave, Italy
  • Solution
    FAST Picking
  • Core technologies
    OSR Shuttle™, depalletizing and palletizing machines
  • Storage locations
    13,968

Estuario Carni supplies various supermarkets in Northern Italy with its high-quality meat products. Goods from two production locations must be centrally processed and distributed. At the DC in Noventa di Piave, the FAST Picking solution by KNAPP handles the job. An OSR Shuttle™ is the heart of the automation solution which also includes depalletizing and palletizing machines.

The solution at Estuario Carni minimizes physical strain for employees such as heavy lifting and carrying while also increasing efficiency and delivery quality. The solution was installed in the cool area at temperatures from 0–4 degrees Celsius. The installation of the solution across two storeys meant taking full advantage of the available space. The OSR Shuttle™ is located on the upper level and is connected to the other warehouse processes on the lower level through the OSR Shuttle™ lift system.

Fagron

  • Branch
    Healthcare
  • Location:
    Oud Beijerland and Capelle aan den IJssel, Netherlands
  • Solution:
    Special healthcare solution for pharmaceutical compounding
  • Core technologies:
    OSR Shuttle, Pick-it-Easy Health, Autopicker SDA-2000

A specialist in producing customized medicines, Fagron is the world-wide leader in pharmaceutical compounding. The company is represented in 29 countries on 5 continents and supplies about 150,000 pharmacies and 55 countries with high-quality and innovative products.

Up to 1,500 orders are processed daily in a few hours in the Oud Beijerland DC and in minimal space, which called for a powerful, space-effective and secure picking system. The fast-mover autopicker SDA-2000 is the ideal solution: About 80 percent of articles ordered per day are stored efficiently in the SDA and are automatically picked. Automated picking is efficient and guarantees the highest quality. Articles such as tubes or pill bottles, which are not suited to autopicker picking due to their dimensions, are picked with the help of the tube autopicker.

A high-performance state-of-the-art distribution centre was built in Capelle aan den IJssel. The heart of the solution is the OSR ShuttleTM, where most of the assortment is stored making efficient, reliable order processing possible. Every day about 1,500 orders are processed in the warehouse.

The KNAPP solution unites efficiency and quality in a tight space and optimally fulfils Fagron’s requirements. By using the central belt autopickers, 80 percent of orders are automatically processed, and with the tube ejectors, tubes and bottles can also be processed. The orders are completed within a few hours: Orders can be made until 5 pm which can be dispatched by 7 pm.

 

Grene

Logo Grene
  • Branch
    Industry
  • Location
    Skjern, Denmark
  • Solution
    Open Shuttle transport system combined with an automated storage and picking system
  • Core technology
    Open Shuttles, OSR Shuttle™, Pick-it-Easy work stations, KiSoft WMS
  • Order lines / day
    8,500

At the centre of the system is the high-performance storage and picking system OSR Shuttle™ with two rack line systems and 12,000 storage locations. At the two Pick-it-Easy work stations, goods are picked ergonomically and efficiently according to the goods-to-person principle. Along with the powerful Streamline conveyor system, three Open Shuttles also convey goods within the facility. These driverless warehouse vehicles are a flexible and space-effective addition to other conveying means; paths remain free for personnel, forklift trucks and other transport vehicles. Long distances can also be covered without the need to build comparably expensive static conveyors. The integration of the higher-level warehouse management system KiSoft WMS makes managing all the warehouse processes easy.

Grene Denmark specializes in spare parts, hydraulics and products for the agricultural sector. From their 21,500 m2 central warehouse in Skjern, Grene supplies its customers in Denmark, Sweden, Norway and Finland. Fast delivery of goods takes highest priority and customers enjoy the fastest possible delivery for their orders – with next-day delivery at the latest.

Hermes Fulfilment

  • Branch
    Fashion
  • Location:
    Haldensleben, Germany
  • Solution:
    Optimization of returns management
  • Core Technology:
    OSR Shuttle
  • Containers stored per hour:
    2,000
  • Articles picked per hour:
    15,000
  • Dispatches per day:
    up to 250,000

Returns management is a central demand in the fashion area and is the core competence of Hermes Fulfilment. The company belongs to the Otto Group and is a full service provider offering customized services all along the supply chain.

To optimize returns management, Hermes Fulfilment decided to automate part of the returns handling process using an OSR Shuttle™ from KNAPP. The powerful KNAPP solution for efficient and cost-effective returns handling is synchronized with other warehouse processes. Structurally, the OSR Shuttle™ was integrated into the existing building.

The software transmits the ideal storage location for each mixed container. Storing up to 10 various articles in a container permits the optimal balance between storage density and picking performance. Picking is carried out at the Pick-it-Easy work stations. The work stations are designed with intelligent KiDesign and unify efficiency, ergonomics and multifunctionality. The computer controlled user guidance guarantees error-free work.

The safety of the OSR Shuttle™ was confirmed by TÜV Rheinland. The system is completely enclosed by a fence and can only be entered through an interlock system. All access points are secured by sensors and the system also has a fire protection sprinkler system. Servicing platforms and other platforms are available for maintenance of the system.

JCL LOGISTICS

Logo JCL
  • Branch
    Fashion
  • Location
    Werndorf, Austria
  • Solution
    Omni-channel fulfilment
  • Core technologies
    OSR Shuttle™, Pick-it-Easy work stations (B2B), Sort & Pack stations (B2C)
  • Throughput per year
    28 million B2B, 3.5 million B2C

Over 50,000 m² in Werndorf, JCL erected a highly modern, multifunctional logistics hub for supplying customers in Austria, Switzerland, Hungary, Slovenia and parts of Germany. The main requirement was the automatic processing of folded and hanging goods from start to finish in the core business area B2B. Additionally, a separate area for the handling of B2C business was created, where the demands of e-commerce are catered to.

The central theme of the customer’s requirements for KNAPP was: “Make people the focus of the logistic solution”. Therefore, ergonomic workstations with daylight and optimized work processes were very important elements of the defining concept.

John Lewis

Logo John Lewis
  • Branch
    Retail
  • Location
    Milton Keynes, UK
  • Solution
    Omni-channel at its best
  • Core technologies
    OSR Shuttle™, YLOG-Shuttle, Pocket Sorter, Pick-it-Easy work stations, KiSoft WMS
  • Order lines per day
    B2B: 170,000; B2C: 55,000

John Lewis (JL) is one of the leading department stores in the UK and comprises diverse companies such as John Lewis Stores and the supermarket chain, Waitrose. In order to further strengthen and expand its market-leading position in omni-channel retail, JL relies on its partnership with KNAPP. The Magna Park distribution centre is the heart and logistics hub of the John Lewis distribution network, allowing the company to set new standards in customer service.

The KNAPP solution means an enormous increase in capacity for the distribution networks and forms a base for planned growth. The innovative automation solution offers JL numerous advantages and fulfils all its requirements pertaining to efficiency, ergonomics, potential to make savings and flexibility. The intelligent omni-channel solution combines all the distribution models of JL: the availability of goods is optimized for both stores and end customers. Shop-friendly picking raises the level of service at stores and significantly reduces the amount of work required at the point-of-sale.

Lotte Mart

Logo Lotte Mart
  • Branch
    Food Retail
  • Location
    Gimpo/Seoul, South Korea
  • Solution
    E-Grocer
  • Core technologies
    OSR Shuttle™, Pick-it-Easy work stations, OSR Shuttle™ Sorter
  • Performance per day
    170,000 items (100,000 shelf-stable items and 70,000 fresh and frozen food items); (one-shift operation)

Lotte Mart, the leading food retailer in South Korea, offers an online shop for groceries – Lotte Mart Mall. Thanks to the KNAPP solution for the Seoul DC, customers receive same-day delivery of fresh items ordered online.

The system solution E-Grocer allows the company to process 10,000 orders a day. Articles from the dry, fresh and frozen range are picked under optimal ergonomic conditions in three different temperature zones. The solution uses the powerful storage and goods-to-person picking system, the OSR Shuttle™. The OSR is also able to process a large number of delivery routes simultaneously. Thanks to the efficient master concept and technologies, and control mechanisms used, Lotte Mart is able to guarantee its customers a very short delivery time and high quality.

Louisiana Wholesale Drug

  • Branch
    Healthcare
  • Location:
    Sunset, Louisiana, USA
  • Solution:
    Security and quality with Vision technology solution
  • Core technologies:
    Automated picking: Central Belt System with SDA ejectors. Quality assurance: Vision Item Check and Vision Central Belt. Paperless picking: RF terminals. Handling: Fully-automatic dispatch preparation. KiSoft WCS software
  • Highlights:
    Automatic data capture from 1D and 2D codes (serial numbers, lot information, date marks). A 100% check in the automated picking areas.

Louisiana Wholesale Drug Company (LWD) was founded in 1979 when a group of independent pharmacists recognized the need to offer their patients a comprehensive range at the best price with top-quality service. LWD now comprises 178 pharmacists who run a total of 250 pharmacies. To support further company growth, LWD decided to expand and automate the DC in Sunset, Louisiana.

Fast-moving medicines are picked completely automatically using the proven Central Belt System. The Central Belt System is equipped with the Vision Central Belt add-on, which provides a 100% check for the automated picking area. Vision Central Belt captures the security data such as serial numbers, lot information or date marks, fulfilling legal requirements while increasing efficiency and quality.

In the areas where checks take place, Vision Item Check increases efficiency and fulfils the highest demands for quality. Since Vision Item Check captures data from 1D and 2D codes, it is suitable for applications in goods-in or for the efficient handling of returns. Vision Item Check and the add-on, Vision Central Belt, are easily integrated into existing systems for a reasonable investment.

Marc Cain

  • Branch
    Fashion
  • Location:
    Bodelshausen, Germany
  • The solution:
    High end logistics in function and design
  • Core technology:
    OSR Shuttle, roll adapter system, Pick-it-Easy work stations, Sort & Pack stations, KiSoft WMS and KiSoft WCS
  • Storage locations:
    84,722 for flat-packed goods in the OSR Shuttle, approximately 500,000 items in the hanging goods area

Marc Cain selected a design-oriented new building that which centralized six locations at the headquarters in Bodelshausen and that housed a flexible solution with the most modern technology. Marc Cain selected KNAPP as a partner who understands textiles, for a solution by a single source.

The highly automated solution includes a four-aisle OSR Shuttle™ and a hanging goods area that extends across 5 levels. Over three million items of clothing pass through the warehouse each year and up to 35,000 articles are picked on a daily basis.

B2C orders are processed at separate Sort & Pack stations. During peak periods, up to 1,250 packages are shipped daily. Exclusive online orders are packed with sophistication. The goods are wrapped in tissue paper and dispatched in premium-quality cartons with Marc Cain branding, together with an added gift.

Marks & Spencer

Logo Marks & Spencer
  • Branch
    Retail
  • Location
    Bradford, UK
  • Solution
    Omni-channel retail
  • Core technologies
    OSR Shuttle™, Pick-it-Easy work stations, RF picking
  • Orders per day
    Up to 450,000

The Marks and Spencer Group plc (M&S) is an international retailer of clothing, commercial goods and food. The key factor in favour of the KNAPP solution was the OSR Shuttle™ technologies, which form the heart of the intralogistics system in Bradford. The OSR Shuttle™ supplies the ergonomically designed Pick-it-Easy work stations and processes all medium and slow-moving products in the warehouse with unrivalled efficiency.

The DC operates 24 hours a day, 7 days a week, 365 days of the year. Always on duty – a team of KNAPP Resident Engineers keep the system availability at full steam thanks to their preventative maintenance and fast reaction times. The DC in Bradford supports the 84,000 m² M&S distribution centre in Castle Donington, allowing M&S to optimize delivery efficiency to their stores. Optimized supply improves sales potential in stores and increases customer satisfaction, which is the key to M&S’s competitiveness.

Migros Aare

Logo Migros Aare
  • Branch
    Food Retail
  • Location
    Schönbühl, Switzerland
  • Solution
    Reusables Management Solutions
  • Core technologies
    High-performance sorter, automatic image recognition, automatic stacking/destacking machines and palletizing/depalletizing machines, KiSoft product palette
  • Throughput per hour
    Up to 12,000 handling units

Migros wanted more efficiency in sorting empties at its Schönbühl location and to reduce physical strain for employees. With this goal in mind, they selected an automatic empties sortation system by KNAPP.

Sophisticated KiSoft software and modern technologies cover all the processes involved that are actually behind the point of sale. Components working behind the scenes along with the KiSoft products include: Container and pallet conveyors that track material flow, automatic handling machines, automated guided vehicles, electronic image recognition systems and high-powered sorter.

When it comes to smooth, automatic sortation, the system truly delivers with high availability and an hourly throughput of up to 12,000 crates. In parallel to the sortation of crates, the customer can also run a quality check in the pallet area, covering up to 8,000 pallets a day.

Migros Zürich

Logo Migros
  • Branch
    Food Retail
  • Location
    Zurich, Switzerland
  • Solution
    FAST Picking
  • Core technologies
    OSR Shuttle™, automatic machines for destacking and stacking, as well as depalletizing and palletizing, KiSoft
  • Performance
    Up to 90,000 handling units per day

Every day at Migros in Zurich, up to 1,400 different dairy, convenience and catering articles, including baked goods, arrive on site either in standardized Migros handling units or in foldable crates. Manually handling such heavy units would place tremendous strain on the employee. KNAPP comes to the rescue with FAST Picking – an automatic, high-performance picking system.

Articles arriving at the warehouse are automatically depalletized, stored and palletized for shipping to stores. An OSR Shuttle™ System with 12 aisles, 7 levels and 12,500 storage locations is the heart of the solution. The automatic destacking and stacking modules cover three functions; pallets are destacked, the units are then placed on trays for short-term storage in the OSR Shuttle™ and finally pallets are built with the units according to order. KiSoft Pack Master calculates the optimal pallet image so that the handling units are stacked in a shop-friendly manner. The solution supplies around 150 stores both accurately and cost-effectively.

MSG Mechatronic Systems

Logo MSG
  • Branch
    Industry
  • Location
    Wies, Austria
  • Solution
    Flexible supply for production work stations
  • Core technology
    YLOG-Shuttle
  • Production work stations
    6

At automobile supplier MSG Mechatronic Systems, the YLOG-Shuttles store raw materials from the goods-in area, supply the work areas and provide materials to the staff at an ergonomic picking level. The YLOG-Shuttle system also features flexible, temporary storage for semi-finished and finished products.

The YLOG-Shuttle System is coupled by interface to SAP Business One, providing the strict lot management the MSG needed. Particularly meaningful was the way the system takes into account the specific hardening time in the production process. The shuttle system eliminates storing things on the floor and forklift traffic in the production area. Flexible, temporary storage is efficiently connected to the various work stations, which have different cycle times. The system can be expanded easily in the future in terms of storage locations and performance.

Novaltia

Logo Novaltia
  • Branch
    Healthcare
  • Location
    Zaragoza, Spain
  • Solution
    Top automation for pharmaceutical distribution
  • Core technologies
    OSR Shuttle™, KNAPP-Store, Pick-it-Easy, Open Shuttle, KiSoft
  • Degree of automation
    95 percent

Novaltia operates four distribution centres and delivers to around 1,000 pharmacies, up to five times daily. The majority of picking procedures in the distribution centres are automated in order to process enormous order volumes of up to 120,000 articles per day efficiently and securely.

KNAPP continues to work with Novaltia as a partner in logistics, expanding and modifying the existing distribution centres. The DC in Zaragoza is an innovative complete solution with central belt technologies, OSR Shuttle™ with goods-to-person work stations, comprehensive KiSoft software solution and a stacker crane.

Novaltia has opted for the KNAPP-Store for the efficient and safe handling of slow-moving articles, returns, and articles that are subject to stringent legal regulations. The free-moving Open Shuttles cover the complex conveying stretches within the warehouse. When humans reach the limit of their capabilities, the Pick-it-Easy Robot takes over. The robot really delivers – high performance at a steady rate and top picking quality.

Olymp

Logo Olymp
  • Branch
    Fashion
  • Location
    Bietigheim-Bissingen, Germany
  • Solution
    Store-friendly delivery with matrix sortation
  • Core technologies
    OSR Shuttle™, Pocket Sorter, Pick-it-Easy work stations
  • Storage locations
    265,000 (OSR Shuttle™)

OLYMP Bezner KG is the market leader for premium men’s clothing, offering modern design, high product standards and great quality for a great price.

In their made-to-order DC, OLYMP has an OSR Shuttle™ with 265,000 storage locations, which provides temporary storage for the dispatch area and which supplies the pocket loading stations. Two pocket sorters are downstream of the OSR Shuttle™. This means every dealer receives the required shirts, ties, polos and knitted goods in a sequence based on customer request as a package – in short, shop-friendly.

Control system KiSoft WCS and ergonomic, employee-friendly work stations complete the KNAPP solution. With this system, there is plenty of flexibility for OLYMP’s order structure, allowing B2B and B2C orders to be processed at the same time.

Pankl High Performance Systems

  • Branch
    Industry
  • Location:
    Kapfenberg, Austria
  • Solution
    Smart production – the person at the centre of digitalization
  • Core technologies:
    Storage system: YLOG-Shuttle system with 4,368 storage locations. Assembly and quality assurance: 4 ivii.smartdesk work stations. Software: KiSoft One, KiSoft SRC, easyUse user interfaces
  • Performance:
    Up to160,000 drivetrains per year = 3 minutes per drivetrain
  • Highlights:
    End-to-end zero-error strategy across the entire production process, 100 % personalized traceability, gamified assembly processes

Pankl Racing AG, headquartered in Austria, is part of the international KTM group and specializes in the areas of aerospace, racing and high performance. Pankl High Performance Systems is a new division of Pankl Racing AG and produces high-quality drivetrains for motorcycle applications for KTM at its new site in Kapfenberg. The high production performance of up to 160,000 items per year led to the entire value creation being pooled under one roof. In total, 12 different types of drivetrains are manufactured for both on and offroad driving. Along with high performance, optimum quality is crucial to all of the processes. This is why Pankl chose an innovative solution from the KNAPP group’s portfolio for its assembly area.

Semi-finished parts and bulk material are stored centrally in the YLOG-Shuttle system. The shuttles can change between levels and rack line systems, allowing them to reach every single storage location in the rack system. The shuttles retrieve the parts required for assembly and bring them directly to the ivii.smartdesk work stations. Here, assembly is guided by software with a real-time feedback system. During assembly, the system records all the parts, checks that they have been correctly installed and informs the employee of the result. Green means that everything is correct whereas red means there is an error. In the event of an error, ivii.smartdesk assists in the correction process.

The KNAPP solution combines maximum performance and efficiency with a zero-error strategy, and provides personnel with a modern working environment. Gamification of the assembly steps motivates personnel and helps to establish a learning organization.

Phoenix

  • Branch
    Healthcare

ProServ

Logo ProServ
  • Branch
    Healthcare
  • Location
    Pulheim-Brauweiler, Germany
  • Solution
    all-in shuttle
  • Core technologies
    OSR Shuttle™, KiSoft
  • Degree of automation
    Up to 100 percent

ProServ is a full service provider and supplier in the health industry, serving health facilities in the Cologne area. ProServ selected KNAPP’s comprehensive, future-oriented all-in-shuttle solution.

The key technology is the OSR Shuttle™, which covers all the most important warehouse processes centrally, including: space-effective storage of containers up to 30 kg, replenishment management for refilling all flow racks and dispatch buffering of all load carriers, container sequencing

The warehouse management software KiSoft WMS controls, monitors and manages numerous processes ranging from goods-in, stock and storage location management, picking, replenishment control, cross-docking and the handling of returns, ensuring smooth warehouse operations.

Generating a precise sequence of containers yields clear improvements in delivery quality and speed. Manual and automated work processes are harmoniously integrated in the warehouse. Special focus was placed on the ergonomic design of all manual work areas and the intuitive operation of the user interfaces.

Recreational Equipment, Inc. (REI)

Logo REI
  • Branch
    Fashion
  • Location
    Goodyear, Arizona, USA
  • Solution
    Omni-channel fulfilment
  • Core technologies
    OSR Shuttle™, Pocket Sorter, Pick-it-Easy Multi work stations, KiSoft
  • Sorting performance
    Up to 7,500 items/h (Pocket Sorter)

Thanks to the chaotic storage in the OSR Shuttle™ and to the RFID technologies of the pocket fulfillment system, REI has access to every article in the system at all times. Goods from the OSR Shuttle™ and sorter pockets are picked at the hybrid work station Pick-it-Easy Multi. Using the goods-to-person principle means that every article is only touched once. The ergonomic design of the work station and the smart user guidance with easyUse create a comfortable working environment and reduce the time needed to train new employees.

The Goodyear DC supplies REI stores with new and replenishment goods, and processes online orders for the services Pick-from-Store or direct shipping to the end customer. The warehouse control software KiSoft WCS monitors, optimizes and controls all the processes in the warehouse and ensures an even supply of orders to the work stations.

Deliveries arrive at the REI shops already sorted according to theme, colour and size thanks to an innovative sorter matrix. This saves store employees a great deal of work as they put away the goods, and frees up time for consultation with customers.

SPAR Austria

Logo Spar
  • Branch
    Food Retail
  • Location
    Ebergassing, Austria
  • Solution
    Flexible Case Picking
  • Core technologies
    OSR Shuttle™, Pick-it-Easy Move work stations, Pick-it-Easy Tray work stations, Open Shuttles for pallets, RMS
  • OSR Shuttle™ storage locations:
    38,400 for shelf-stable goods, 58,688 for fresh foods

SPAR wanted to be able to react flexibly to all the demands of food retail, and together with KNAPP, they built the most modern DC of its kind in Ebergassing. The solution is a semi-automatic one, but it provides the same performance as a fully-automatic one at a far lower investment figure. Responding to peaks in the food business is also possible without necessarily designing the warehouse just for this peak.

Through innovative technologies, the new warehouse for fresh foods and dry goods achieves the flexibility it was designed to have. The Open Shuttles are responsible for transporting pallets within the warehouse, and navigate autonomously and freely without physical or optical aides. Picking is particularly ergonomic: at the Pick-it-Easy Move work stations fast-moving articles are picked directly from the goods-in pallet to the roll container. Medium and slow-moving articles are temporarily stored on trays in the high-performance storage and picking system OSR Shuttle™. Then the roll containers for orders are assembled at the Pick-it-Easy Tray work stations. The RMS system is used to handle empties.

Tudespensa.com

Logo tudespensa
  • Branch
    Food Retail
  • Location
    Madrid, Spain
  • Solution
    E-Grocer
  • Core technologies
    OSR Shuttle™, Pick-it-Easy work stations, automatic stackers, KiSoft
  • Performance
    67.000 items / 27.000 order lines in 15 hours

The online food retail company, tudespensa.com in Madrid, supplies more than 130,000 customers throughout Spain. For the satisfaction of the end customer, particular care was taken to ensure that the solution handles the special demands of e-commerce.

KNAPP made the E-Grocer system concept a reality in the Madrid DC. Two OSR Shuttle™ systems comprising five rack lines form the heart of the warehouse. Two rack line systems with 9,216 storage locations are provided for double-deep storage of the dry goods range. 4,680 storage locations are included in the other three rack line systems, which store the fresh foods and provide interim storage for dispatch. The five Pick-it-Easy work stations ensure highly ergonomic picking for medium and slow movers based on the goods-to-person principle. Fast movers are picked directly from the pallet to the shopping bag, which is an optimal combination of manual and automated processes. With this approach, order lead time is drastically reduced.

TUŠ

Logo TUS
  • Branch
    Food Retail
  • Location
    Celje, Slovenia
  • Solution
    Paperless picking
  • Core technologies
    OSR Shuttle™, KiSoft Pick-to-Light, KiSoft Voice, RF picking, KiSoft Automove
  • Throughput per day
    1,500,000 items

In the TUŠ warehouse in Celje, Slovenia, various KNAPP technologies are used to enable paperless processing for all warehouse processes. Among other things, an OSR Shuttle™ is used with three work stations in two different temperature zones. Several forklifts independently navigate the warehouse with the help of KiSoft Automove and handle various transport tasks. KiSoft Pick-to-Light, KiSoft Voice and RF picking support the manual picking. Warehouse management and control of all processes is handled centrally by KiSoft WMS.

The end-to-end, paperless flow of goods and information without a change of media increases the quality of delivery while reducing error sources. KNAPP’s solution offers a significant increase in throughput in the fresh and refrigerated area.

Weisser

Logo Weisser
  • Branch
    Industry
  • Location
    Neresheim, Germany
  • Solution
    Flexible and space-effective solution across several levels
  • Core technology
    YLOG-Shuttle
  • Load carriers
    13 different carton types and containers

Faster delivery times and increasing orders led Weisser to relocate its decentral warehouses to the central production location in Neresheim. Weisser decided to build a 20-metre-high hall with 3 levels to make best possible use of the small space available. Bearing this in mind, a YLOG-Shuttle system was constructed with 37,000 storage locations for 13 different types of cartons stored either one or two deep. Three Cross Lifts are installed on the long side of the rack, connecting the ground floor with the racks on the upper floors. Retrieval and storage conveyors supply the cartons to the ergonomic work stations before they are stored once again. A number of easyUse user interfaces guide employees through the work process, ensuring efficient and accurate order processing.

Weisser Spulenkörper GmbH & Co KG was founded in 1922 and is a leading producer of technical plastic parts, manufacturing high-quality bobbins and housings for sensors, magnets, transformers, relays and motors.