Case Study Triumph - Apparel Distribution - Industries - TGW Logistics Group

Case Study Triumph

Triumph trusts in so-called Silo Sharing: three different storage systems are located under the same roof

Case Study Triumph
  • MODERN WAREHOUSE REPLACES OLD SOLUTION

    By installing a modern European central warehouse at the Wiener Neustadt site in Austria their first semi-automated high bay warehouse which had been put into operation 20 years ago was replaced.

DISTRIBUTION CENTRE IN WIENER NEUSTADT

Triumph International started as a modest corsetry manufacturer and in more than 100 years turned into a multinational company with 43,000 employees worldwide and an annual revenue of 2.47 billion Swiss Franc. Privately owned till today, Triumph is a reputable manufacturer of underwear, nightwear, youth clothing as well as swimwear and sportswear

Traditionally the company counts on innovative developments and trend-setting projects. By installing a modern European central warehouse at the Wiener Neustadt site in Austria their first semi-automated high bay warehouse which had been put into operation 20 years ago was replaced. Today they trust in so-called Silo Sharing: three different storage systems are located under the same roof: a pallet high bay warehouse, a mini-load system for cartons and a semiautomatic retrapick warehouse for order picking underneath.

REQUIREMENTS & PREREQUISITES

  • storage capacity of more than 147,000 storing positions
  • takeover of up to 2,250 cartons per hour
  • storage and retreival of 191 pallets per hour in high bay warehouse
  • storage and retrieval of 224 pallets in supply warehouse
  • 2,259 picks per hour in retrapick area sorting of 3,000 cartons per hour

 

SOLUTION

Packed goods are supplied by the in-house production as well as other European sewing plants and received on pallets in Wiener Neustadt where they are handed over to the conveyor system for storage. The pallets from the ground floor are transported up by means of a vertical conveyor and combined with the pallets coming from the upper floor. Once the pallets have been checked and captured in the warehouse management system, they are stored in the pallet warehouse or the retrapick area.

The retrapick area is an order picking warehouse which is served by manned stacker cranes. The cartons are directly picked from the pallets in the rack and deposited onto the conveyor system. The pallets are handed over to the storage and retrieval machines and retrapick aisles by transfer cars.

Empty pallets from the retrapick area are returned to the conveyor system and collected by a transfer car. An integrated turntable relocates the pallets from the high bay warehouse to the retrapick area. Pallet stacks are automatically built for the buffering of the empty pallets which are then located in the pallet warehouse.

The individual cartons from the production are directly stored in the carton warehouse to be used for fully automatic order picking later on. After the cartons have been entered in the system and labelled, an employee puts them onto the TGW conveyor system. The barcode label clearly identifies each carton in the system. At intersections or junctions the labels are read by a scanner and the cartons are transported in the right direction.

In order to be stored the cartons have to be transported upwards into the carton pre-storage area via a continuously operated vertical conveyor. Rigid-backed carrier grids take over the cartons from the roller conveyor and delivers them at the top end of the Z conveyor.

The conveyor system then distributes the cartons to six rack aisles. Lineal pushers deflect the cartons at right angles to the zone where the cartons are handed over to the stacker cranes.

Six twin-mast TGW automatic storage and retrieval machines handle the cartons in the rack aisles. The Twister load handling device receives up to two cartons simultaneously from the pre-storage zone by means of an integrated belt conveyor and deposits them onto the allocated rack address.

To retrieve a pallet the Stratus stacker crane accesses a storage position and the Twister handling device withdraws the cartons from the shelf. The load is then handed over to the conveyor system in the pre-storage zone. At the same time it is already possible to take over cartons for storage, which permits time-saving double cycles.

Afterwards the picked cartons are reintroduced into the conveyor system and sent on their way towards the shipping area. Via a Z conveyor the packets get down from the tower of the high bay warehouse to the ground level where they started their journey. Together with the cartons coming from the retrapick area they proceed to the shipping area.

Some of the cartons are held back again in order to check if they are correct. If one of the cartons has its barcode label on the wrong side for example, it will be turned around and put back into the material flow. Besides also cartons from the retrapick area which shall be relocated to the carton warehouse are deflected there.

In the shipping hall the cartons are sorted according to shipping tours and stacked onto pallets. Sorting is done by the TGW Zip Sorter. Once the pallets have been secured against humidity by means of a plastic foil, the tours are distributed across Europe.

TGW TECHNOLOGY EMPLOYED

A Twister V was used as load handling device. Thanks to the adjustable side arms of the Twister V telescope it is possible to handle cartons with different widths at the same time. Additionally you can take over or store the cartons individually or two at a time depending on what you need. The exceptionally high acceleration and speed of the telescopic arms allow for a reduction of load cycles in the warehouse. Integrated belt conveyors directly hand the cartons over to the driven pre-storage area.

During implementation it was particularly taken into consideration that it would be possible to adapt the material flow and conveyor system to the constantly growing demands. The masts of the stacker cranes used were thus installed in a way that in case of necessity a second load handling device could be added.

The pallets are sorted according to shipping tours by the Zip Sorter which is a shoe sorter. The cartons are taken over by the so-called sorter mat which consists of individual aluminium profiles. Each profile is equipped with a slide shoe which can be moved crossways and thus can push the individual cartons off the sorter mat. The slide shoes are guided beneath the mat.

Our references

TGW Logistics Group

TGW

NEWS

2015-08-09
TGW expands headquarters in Wels
Until 2018, a new office building as well as a production hall shall be built.">2015-08-09
TGW expands headquarters in Wels
Until 2018, a new...