Central Euro distribution, Gardena Kress + Kastner GmbH in Ulm

Goods-receipt and replenishment storage
Goods are received from suppliers and Gardena factories. After the quality check and recording, the goods, they are automatically transported via a pallet-conveyor system to the highbay warehouse (with 50,000 pallet compartments and integrated picking tunnels). The functions of the existing warehouse-management system were modified and defined in a detailled requirements specification and implemented by S&P during running operations.

Order picking
Due to the centralisation, the volume of 2100 pallets with 60,000 package units for 1000 piece-good and 1200 courier orders have to be picked. Due to the large size of the existing system and the handling requirements, articles are picked in two levels. With just a few exceptions, most articles are picked online without vouchers. Articles that can be sorted are picked using the pick-by-light system and receiving conveyors. All other articles are picked using order-picker trucks and wireless mobile terminals.

Highbay warehouse
Normal and special-format articles are automatically provided in the eight picking tunnels by the stacker cranes. Picking takes place on two levels. Empty pallets generated during picking are transported away via hanging conveyor systems.

Order-picking and buffer warehouse
An order-picking and buffer warehouse was built for large-volume articles. Articles that can be sorted are picked using the pick-by-light system and receiving conveyors. Special formats are picked manually using mobile terminals. Replenishment is taken care of by a separate goods-receipt.

Small-quantities storage
Small quantities are either picked with route-optimised pick lists or using online mobile terminals; these are picked order by order in the area for small-quantity storage, packed and allocated to the final packages through the sorter system.

Sorting
All picked articles are consolidated into the ROTA Sorter System by receiving conveyors and transport stretches. The sorting system consists of two loops. The EAN codes of all articles are scanned using two five-sided scannen. After processing of the transmitted data in the WMS, the goal is sent to the sorter-control system. The sorting system ejects the article at the goal and confirms completion of the task to the WMS.

Small orders are ejected in a bundle. They are therefore sorted into order-wise canals of flow racks afterwards. This task is supported by using light displays after processing of the EAN data by the WMS.

Coloured lights show the status of each packing order at each sorter goal.

Pallet pack stations
Movable packing aids help in packing of order pallets at the sorter goals. The packed pallets can be placed onto the non-powered conveyor system. This is equipped with a simple safety feature to let the pallets roll first manually, then automatically to the stretch-wrapper. The pallets are ready for shipping after wrapping.

Packet pack stations
The packet pack stations have movable packing tables. A tote-conveyor system is used to transport the packed packets towards automatic shipping preparation.

Dispatch
By scanning the package number, the shipping papers are printed and allocated. The data are sent by the WMS via EDIFACT to the forwarding service.

Receiving conveyors in picking tunnel

Empty-pallet transport on hanging conveyor system by Schönenberger

Stretch-wrap machine in dispatch area

Datalogic 5-sided scanner reading station