System Integrator Inther Group Optimizes BMW Warehouse in Dingolfing

To accommodate the growing order volume and the increasing demand for fast, timely order fulfillment and delivery of spare parts, the established processes and existing warehouse equipment at the BMW Group location in Dingolfing have been optimized and expanded – further enhancing efficiency and ergonomics in storage, picking, packaging, and shipping.

(Pressebox: Neckarwestheim/Dingolfing) The contract for implementing a comprehensive concept with an Automated Small Parts Warehouse (AKL), intelligent material flows, and integration of state-of-the-art conveyor technology was awarded to the system integrator Inther Group in Neckarwestheim. The Dutch headquarters in Venray supported the extensive analysis, design, and facility planning in advance, as well as the project realization in Dingolfing. Additionally, the Heidelberg consulting and planning company io accompanied the project from the tendering and awarding phase to realization and final acceptance.

As the heart of the logistics facility, Inther set up a new highly automated four-aisle small parts shuttle warehouse (AKL). With a four-deep storage system across 20 levels, the AKL offers an enormous capacity of around 80,000 container storage locations for spare parts. Containers measuring 650 x 450 x 270 mm and a maximum total weight of 30 kg are used. “The shuttles are specifically designed for the requirements of today’s and future small parts warehouses,” explains Stefan Weisshap, Managing Director of Inther Group Germany. “With its four-deep storage, the shuttle AKL offers enormous capacity with compact, high-density storage, and the automation in retrieval accelerates the supply of goods to the picking workstations.” This allows for more items to be stored with less space requirement, increasing throughput speed in order processing.

Workstations from an Ergonomic Perspective

For the picking of shipping orders and their packaging, workstations for picking and shipping packaging have been established. Additionally, three workstations have been installed in the goods receiving area. To connect the AKL and the height-adjustable storage, picking, and packing workstations designed according to optimal ergonomic aspects, Inther implemented an intelligent, dynamic conveyor technology concept, including empty container buffers. The conveyor technology serves the workstations at a speed of 0.8 m/sec on special conveyor routes for source containers, target containers, and shipping cartons.

The picking stations are supplied from the AKL with source containers. The stations are equipped with connected empty container buffers. Spare parts are picked for shipping according to a pick-by-light system into cartons or reusable containers. Carton erectors provide the prefabricated cartons. Accordingly, the conveyor technology is designed for transporting both load carriers. After completing the picking process, the conveyor technology returns the partially filled containers to the transfer points in the AKL. Target containers and cartons are transported via the conveyor route to the four packing stations. The shipping-ready load carriers are directed by the conveyor technology to the shipping area. Automated weight checks in the conveyor route verify the correct picking by comparing with order and master data. Incorrect cartons are directed to a NiO loop.

Conveyor Technology Created According to Bypass Concept

Subsequently, the cartons pass through a carton sealing machine, and containers are capped before an automatic labeling occurs on the conveyor route. “The entire conveyor technology has been created according to a bypass concept,” explains Weisshap. “This allows the AKL and all stations to serve each other as needed to conduct returns more quickly, avoid or circumvent jams or short-term component failures in the system.”

The new automated storage and conveyor technology has also been seamlessly integrated by Inther with existing facility technology. The visualization of the conveyor technology is carried out by the software Zenon, which has been configured by Inther to meet the existing requirements at BMW. The goods receiving processing, picking, and packaging, as well as the workstation dialogues, are controlled by SAP. This also applies to the shuttle system and the document printing for shipping cartons and containers.

High-Performance Automation Solution

With the agreed after-sales services for the maintenance and servicing of the facility, Inther Group ensures long-term reliable availability of the system. “A high-performance automation solution that provides enormous storage capacity, efficient processes, and reliable picking quality for rapid spare parts supply,” summarizes Inther Managing Director Weisshap.

Photo: © Inther Group