Becoming the logistics hub for Middle and Southeastern Europe - that was the goal Lenze was pursuing. Therefore, Lenze invested in a new ultra-modern storage and order picking system for state-of-the-art material handling to guarantee perfect customer supplies. Based on a long-lasting partnership, TGW implemented the core element of Lenze's logistics centre in Asten, Austria.
Objectives and Requirements:
To increase the productivity and ensure smooth customer supplies, several production sites were consolidated at Lenze's new logistics hub in Asten. TGW was entrusted as general contractor to implement the entire logistics solution within the new building in Asten.
Comprehensive software solution for energy management
Lenze's system is monitored and controlled by the TGW CI_LOG Supply Chain Management Software. The warehouse management system as well as the material flow controller and Commander controls are provided by TGW. All these components are connected to the SAP host system via the CI_LOG interface.
TGW's Commander control system provides for efficient energy management within Lenze, implemented by an automatic stand-by mode in the material handling equipment. If no tote movements are requested, the system will switch into stand-by mode. Energy feedback modules were installed in all storage & retrieval machines which immediately convert the braking energy into power for the lifting axis. This measure reduces the operating costs by up to 20 percent.
Mini-load and high bay warehouse by TGW
TGW implemented a 20 metre high, fully automated high bay warehouse with integrated mini-load warehouse accommodating up to 9,000 pallets and up to 18,000 totes, holding more than 20,000 different SKUs in stock. The advantages for Lenze and its customers are obvious: improved availabilities, increased flexibility and reduced lead times. The automatic mini-load warehouse is capable of handling up to 260 storage and retrieval cycles per hour and is served by TGW Magito cranes and Combi Telescopes as load handling device.
Besides the automatic mini-load warehouse, the solution includes four ergonomic order picking workstations with Pick&Pack technology. These workstations permit the picking personnel to pick orders directly into the cartons - without any intermediate step. A further four order picking workstations are connected to the pallet warehouse. Manual pallet handling is now a thing of the past. The goods are automatically conveyed to the picking employee who is able to pick them directly onto the pallets.
The mini-load picking area is connected to the pallet picking area via a sequencing buffer which allows Lenze to operate the two systems independently from each other. The pre-picked totes from the mini-load warehouse are supplied to the pallet picking station in a pre-defined sequence and combined there to one consignment and packed for shipping.
Oxygen-deficient atmosphere for fire prevention
The fire protection topic presented the project teams with a big challenge. Lenze decided for a fire prevention option which massively limits the fire risk in the warehouse beforehand by reducing the oxygen content. The alternative option in form of a sprinkler system as fire protection measure was excluded due to the higher investment costs. The higher operating costs of the oxygen reduction system are more than balanced out by the considerably lower investment costs and by the prevention character.
Lenze and TGW are proud of the forward-looking collaboration, combining technologies of either of them as well as of the material handling installation with 98 per cent system availability they created together. The new logistics hub in Asten made Lenze achieve the goal of optimising the service level for its customers.
"We have much more space now – to the existing 4,800 square metre assembly hall we added the high bay warehouse with an additional 1,650 square metres and the new 3,000 square metre hall. And still, we managed to simplify the material flow in the hall."