Case Study Kärcher - Other Industries - Industries - TGW Logistics Group

Case Study Kärcher

High pressure in spare parts replenishment

Case Study Kärcher
  • 8 ERGONOMIC PICKCENTER WORKSTATIONS

  • 5,200 STORAGE LOCATIONS IN THE SHUTTLE BUFFER

  • KÄRCHER'S LOGO CAN BE SEEN FROM FAR

  • 65,000 ITEMS ARE HANDLED IN THE CENTRE

Solution

With 12.5 million devices sold in the year of 2013 alone, 10,700 employees and sales offices in 60 countries, the cleaning products of Kärcher make their way through the whole world. The route of spare parts for their devices starts in the central warehouse in Obersontheim, Germany. Here, 65,000 items are stored and shipped. TGW realized this project as systems integrator with the individual requirements of the Kärcher business: automated warehouse areas, picking workstations and a high performance consolidation buffer with TGW STINGRAY shuttles.

Automated mini-load warehouse

  • 85,000 storage positions for totes
  • 8 aisles with 77 metres (252 feet) length and 14 metres (45 feet) height each
  • Single-mast stacker cranes TGW Mustang care for single-deep storage and retrieval (158 double-cycles per hour and aisle)
  • Fully automated replenishment of the picking workstations


Goods-to-Person – Small parts picking


  • 8 picking stations with each two source totes and one order tote
  • Two source totes for efficient picking without losing time and fast tote exchange
  • Saving time and distance of each employee
  • Ergonomic design and high picking performance
  • Inclined arrangement for ideal vision and distance to reach
  • Picking of bigger items in other areas


Consolidation buffer – TGW STINGRAY Shuttle System

  • Consolidation of large-scale customer orders into one package
  • Two aisles buffer storage with 5,200 storage positions
  • 36 TGW STINGRAY shuttles care for 1,800 storages and retrievals per hour

Empties buffer

  • Stacker and destacker with a performance of 1,100 totes per hour
  • Capacity: 600 totes


Order consolidation and packing

  • Few packages for the customer enables a reduction of packaging costs
  • Smaller items arrive from the shuttle buffer, bigger ones are provided manually
  • Working focus adapted to Kärcher dispatch conditions in terms of time


Automated pallet high bay rack

  • 5 aisles for automated storage and retrieval of pallets
  • Pallet conveyor equipment to connect the high bay rack
  • 3 connected picking stations


Objectives and requirements:

  • Central warehouse solution for fast spare parts replenishment
  • Supply of end customers as well as shops
  • System for season peaks
  • Storage and transport of various article sizes
  • Employee-friendly picking solution
  • Order consolidation of various warehouse areas
  • Adapted solution for further growth


Customer Benefits:

  • Modular and adaptable TGW system for future growth
  • Several storage and picking areas for individual process steps according to goods’ size
  • Fully automated replenishment of picking stations due to the automated tote warehouse
  • Goods-to-Person improves the employees’ situations – Ergonomics at the workstation, no walking times
  • Easy handling of picking workstations with light signals for high picking performance
  • Increased customer service by consolidating several orders into one package
  • Shuttle warehouse as high performance consolidation buffer for few packages despite multiple orders
  • Ware-zur-Person verbessert Mitarbeitersituation – Ergonomie am Arbeitsplatz, keine Wegzeiten
  • Decrease of throughput time of orders in the distribution centre – orders with just one position require 30 minutes until dispatch
  • One-stop solution – TGW offered Kärcher an entire system for diverse functionalities instead of single devices

 

"The shuttle systems allows us to retrieve the goods at the latest possible time to consolidate the goods into one package and ship it to the customer. Therefore, we are able to prepare as few packages as possible for our customers. And if the customer orders several times a day, we are aiming at consolidating these orders into one package too.”
Roland Fahrmeier, Vice President Logistics Management at Kärcher

ROLAND FAHRMEIER
VICE PRESIDENT LOGISTICS MANAGEMENT AT KÄRCHER

"We searched for a systems integrator, covering as many aspects as possible. TGW offered all these features: they were able to do the engineering, they were able to program the respective software, and they could do more for us than building 'just' a mini-load warehouse, a P&D area for the high-bay warehouse or a shuttle, they were able to implement the entire solution."