Case Study Rossmann - Food & Grocery Retail - Industries - TGW Logistics Group
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Case Study Rossmann

Handle incoming orders fast and efficiently

Case Study Rossmann
  • ALL AREAS ARE CENTRALLY CONNECTED

    All areas are centrally connected via a high-performance overhead monorail system which disposes of 32 separate vehicles each equipped with an own drive.

LOGISTICS UNDER THE SIGN OF THE CENTAUR

A very broad and high-class range of products, best service for the customers and an extensive, modern store network make Rossmann one of the leading companies in the German drugstore market.

Over 1,200 chain stores in Germany and about 17,500 different articles require an elaborate logistics concept to which technology and staff in the new logistics centre in Landsberg make a considerable contribution.

OBJECTIVES

  • Handle incoming orders fast and efficiently
  • Guarantee goods availability for the chain stores
     

SOLUTION

The automatic pallet high bay warehouse serves for stockkeeping and supply of the picking zones on a minimum space required. Seven railbound stacker cranes assume storage and retrieval of the goods. Each handling machine is equipped with two telescopic forks which can take over two pallets from the conveyor system in the pre-storage area at the same time and deposit them in the rack, allowing for high performance. The compact high bay warehouse can accommodate 37,000 pallets.

Large-volume articles and goods with very high throughput such as current special offers are directly picked from the pallets and consolidated in roller containers to deliver them to the stores. Empty roller containers are supplied to the picking personnel via an automatic conveyor system and a high-performance belt lift on two of the three picking levels. The pallets are provided in the picking aisles on flow racks.

Four stacker cranes are responsible for the supply of the goods pallets, return of the partial pallets into the high bay warehouse and disposal of the empty pallets.
 

OVERHEAD MONORAIL SYSTEM

All areas are centrally connected via a high-performance overhead monorail system which disposes of 32 separate vehicles each equipped with an own drive. Riding on a 440 m long rail the vehicles transport a pallet through large parts of the logistics centre, connecting the goods receiving area with the high bay warehouse and pallet picking zone. Up to 400 pallets per hour are taken to the right place by this system.

Articles with lower throughput rates as well as single deliveries are brought to the repacking area where the goods are repacked from the pallets into storage totes. This is necessary in order to be able to concentrate the largest possible range of articles on the least possible space in the picking areas.

The repacking area disposes of more than 20 semi-automatic repacking stations on one level. Each workplace has a lift table by means of which the worker can adjust the height of the pallet in a way that he can pack the goods from the pallet into a tote without having to bend down and lift them up. There are two red storage totes available in the system in different sizes. The corresponding tote is automatically provided to the worker for each article.

A high-performance conveyor system transports the totes into the automatic small parts warehouse (mini-load) where the goods are picked in the rack aisles.

AUTOMATIC SMALL PARTS WAREHOUSE

The automatic small parts warehouse (mini-load) assumes two functions: on the one hand it serves as buffer warehouse between goods receiving or repacking area and the picking system, on the other hand it permanently provides the picking workplaces with goods.

Four 15 m high TGW stacker cranes of the type Stratus supply 22,760 storing positions in the buffer warehouse. Each of these handling machines are equipped with two load handling devices of the type combi telescope C. As the goods always come from the repacking area in single-item totes, they can be stored and retrieved in the warehouse without sorting, which increases the throughput considerably.

The remaining five Stratus stacker cranes serve the flow racks in the new order picking system.
 

ZONE-TO-ZONE PICKING SYSTEM

Grey collapsible boxes with a dimension of 600 x 400 mm are used as order totes in Rossmann’s distribution centre. The stores send these boxes back to the warehouse folded, which saves a lot of space. There the boxes have to be automatically unfolded by a machine. Up to 600 boxes per hour are identified with a barcode label, allocated to a store order and, together with a picking list, handed over to the subsequent conveyor system.

The conveyor system which is designed for a performance of 1,200 totes per hour in this area automatically supplies the required order totes to the 36 order picking stations on two levels of the zone-to-zone picking system. As soon as a tote reaches a picking zone from where it shall receive goods for the respective store, it is deflected from the main conveyor line onto a parallel roller line of the respective picking station. A pick-by-light display informs the picker at this station which quantity he has to retrieve from which storage tote. When all required goods have been deposited into the order tote, it is pushed back onto the main conveyor line and automatically transported to the next station. This order picking method permits a considerable reduction of the staff’s picking time and an optimum utilisation of the available storage space.
 

GOODS ISSUE

The goods are delivered to the Rossmann chain stores in roller containers. Therefore, up to 1,200 order totes have to be packed into roller containers in the two goods issue areas in the old and new building. Together with the roller containers coming from the pallet picking area they are provided for truck loading. An average of 7,000 roller containers leave the Rossmann distribution centre every day and are distributed to stores all over Germany.
 

TGW TECHNOLOGY EMPLOYED

The TGW conveyor system handles up to 2,000 totes per hour and connects the repacking area with the nine aisles of the automatic small parts warehouse, the zone-to-zone picking area in the new and old building as well as the final workplaces for goods issue by means of several conveyor levels. The partially mixed transport of order totes and the two different dimensions of the totes posed a special challenge during the implementation of the new system. The small storage totes are conveyed in cross direction, but have to be turned 90° before they are handed over to the conveyors of the existing picking system.

For further information on the company please visit the Rossmann website at www.rossmann.de.

Our references

TGW Logistics Group

TGW

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