High-tech Shuttle System for DRiV
DRiV is the aftermarket division of Tenneco, a supplier to the automotive industry. The Willebroek location in Belgium is home to the European DC for the aftermarket segment and supplies end customers and retailers with car parts. Each year, the DC ships millions of spare parts from two million product lines.
To optimize customer service, DRiV decided to implement an Evo Shuttle system to augment their high-velocity supply chain strategy. The solution offers tremendous storage density and works efficiently even when customer demand increases.
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More InformationThe new automation solution resulted in an overall increase in productivity of 35 percent for the location and raised the storage capacity by more than 30 percent.
Raphael Zagni
DC Operations Director EMEA
Tenneco Inc.
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New warehouse system for high-speed supply chain in the European region
With the new automation solution, DRiV aims to optimize customer service and set the benchmark for a next-level DC. To implement this automation solution, DRiV sought a partner who understood their challenges. Criteria in the selection of a new partner included company size and presence, IT approach, available services and references. DRiV selected a comprehensive solution featuring the Evo Shuttle automated small parts warehouse, Pick-it-Easy work stations, decanting and shipping work stations as well as the software KiSoft FCS for their fleet. The solution offers a multitude of advantages.
Next-level picking and maximized storage density
The heart of the new system is the Evo Shuttle, an automated small parts warehouse with space-effective triple-deep storage. Five goods-to-person work stations of the Pick-it-Easy series were installed to allow picking directly into shipping cartons. Another part of the efficient solution is an automated packing line featuring volume reduction. Before arriving at the shipping ramps, the cartons are checked for errors, weighed and volume-optimized before being closed and given their address labels. This process requires no human intervention, saving resources, and also results in sustainable package sizes.
The so-called mind of the automation solution is the all-in-one software, KiSoft One, which connects DRiV’s warehouse management system, Manhattan. KiSoft controls and coordinates storage, picking and shipping.
With the new solution, lead times were significantly reduced. This gives us additional potential for growth in the e-commerce segment and for us to care for our rapidly growing base of regular customers.
Thomas Vandael
Executive Director Supply Chain EMEA
Tenneco Inc.
DRiV’s innovative solution at a glance
The new shuttle system started operating at the Willebroek location in 2023. The automated small parts warehouse and automating packaging processes have accelerated throughputs and are conducive to e-commerce growth.
1) Goods-in
Goods are delivered on pallets. They are stored temporarily on floor locations and then brought to the high-bay racking system for pallets or to the decanting work stations. At the work stations, the goods are separated and repacked into containers or cartons. The height and weight of the load units are checked, after which they are conveyed to either the Evo Shuttle or to the manual warehouse.
2) Storage
The Evo Shuttle offers space for 55,000 containers, storing the goods triple-deep on 27 levels and in two aisles. The 54 shuttles provide smooth processes in the warehouse, bringing small parts to picking as needed. Large items are stored as usual in the existing high-bay racks.
3) Picking
The picking area is located on a mezzanine above the shipping area. In a goods-to-person process, orders are brought from the Evo Shuttle to the five Pick-it-Easy work stations, where they are picked directly into shipping cartons. The weight is automatically checked to ensure error-free picking.
4) Packaging
After the documents are automatically printed and inserted, the still-open cartons meant for direct shipping are conveyed to the automatic carton closer, where the machine reduces the cartons to the minimum size. All cartons that cannot be automatically closed are conveyed to one of the four manual packing work stations. Afterwards, the shipping labels are applied by machine, and the cartons are ready for onward transport.
5) Shipping
Cartons leaving the packing area are conveyed by order to the shipping ramps on the ground floor. Orders coming out of the automated small parts warehouse, the manual warehouse and the pallet storage area are consolidated here. Finally, the orders are shipped to the customers.
Storage locations in the Evo Shuttle
Multifunctional work stations
Shuttles
Items per day
m² warehousing space (290,626 ft²)
Shuttle system at DRiV is key to great customer service
Effective partnership for shared success
By choosing KNAPP, DRiV has a partner that provides the software as well as the hardware. From the beginning, both partners shared the same values: commitment, critical thinking and flexibility – also in terms of keeping critical deadlines. Cooperation was outstanding throughout the entire process, from initial inquiries and ultimately to the go-live. Open dialog between DRiV and KNAPP was always part of the process. The management and the teams from both companies worked together harmoniously, which helped to speed decisions. The automation project was implemented within 18 months during the global supply chain crisis and blended seamlessly with existing infrastructure. The successful collaboration and implementation of the project has also prompted DRiV to consider further improvements in the automation of the warehouse.
With KNAPP, we have a partner to rely on who shares our attitude towards commitment, collaboration, critical thinking and flexibility.
Thomas Thys
PMO Director EMEA
DRiV
