witron opm technology for the frozen goods...

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Date: October 4, 2012 - Page: 1© Copyright WITRON, 2012

Frozen goods central warehouse for

production and trade goods including

small volume order picking in Brehna

- 24 C

Low Temperatures – High Cost-Efficiency

WITRON OPM technology

for the frozen goods environment



Date: October 4, 2012 - Page: 2

EDNA – Manufacturer of frozen bakery products




EDNA – Facts & Figures




EDNA – Layout – Ground Level

Central warehouse for production and

trade goods including small volume order

picking in Brehna




Fully-Automated

Picking of Cases

System Components – Concept OPM




OPM = Order Picking Machinery

Characteristics

� Mechanization of all process steps from receiving to dispatch

� Fully-automated picking of order pallets with the case order machine „COM“

� Use of trays for cases guarantees high system availability

� Fully-automated picking of a variety of different trade units

� Use within fresh goods and frozen goods is possible

� Optimum pallet stability and loading through computer-controlled sizing matrix

� The total number of SKUs is the basis of using a sequence buffer rack or sorting with the

tray warehouse/conveyor

� OPM system with smallest footprint avoids non-ergonomic picking efforts

� No engagement of personnel resources within order picking

System Components – OPM – Characteristics




System Components – OPM – Material Flow

OPM

Receiving

Pallet Highbay Warehouse

Mechanized depalletizing

Mechanized tray loading

Mechanized tray storage

Shipping

Mechanized picking with the Case Order Machine (COM)

Order Pallet Separation and Stretching




� Order pallet is calculated by using

pack pattern software before

building it in the COM machine

� Every COM fed by a sequence

buffer

� Maximum stability and volume on

the order pallet will be enabled

due to picking into pack corner.

Fences of roll cages will be

automatically spread during picking.

Allocation of a picking wall behind

the roll cages enable secure

picking process

� Complete order pallets are

stretch-wrapped on ground level as they are

automatically lifted out of the pack corner

System Components – OPM – Case Order Machine




System Components – OPM – Highlights

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OPM – Success Story / No Innovation without Tradition

Foundation of WITRON

First big design project

First big order with overall project responsibility

A.T.U., WeidenA.T.U., Weiden

Foundation of the subsidiaries in USA and UK

SPAR, WelsSPAR, Wels

LIBRI, Bad Hersfeld LIBRI, Bad Hersfeld

Development of modular logistics solutions

SAINSBURYSAINSBURY´́S, S, StokeStoke + + HoddesdonHoddesdon

KROGER, KROGER, TollesonTolleson

Start of the OPM success story

KROGER, Aurora / MERCADONA, MadridKROGER, Aurora / MERCADONA, Madrid

EDEKA, HammEDEKA, Hamm

SUPERVALU, HopkinsSUPERVALU, Hopkins

Implementation of OPM in the fresh goods and frozen goods

environment

SOBEYS, Toronto / MERCADONA, SOBEYS, Toronto / MERCADONA, RibarrojaRibarroja

Manufacturing of own conveyor system elements

New OPM generation

KROGER, Compton / KROGER, Paramount / SUPERVALU, LancasterKROGER, Compton / KROGER, Paramount / SUPERVALU, Lancaster

MIGROS, MIGROS, Suhr / Suhr / MERCADONA MERCADONA Leon Leon

COOP, Oslo / SOBEYS, Montreal / TARGET, DallasCOOP, Oslo / SOBEYS, Montreal / TARGET, Dallas

CONDIS, CONDIS, MontcadaMontcada / EDEKA, Landsberg / EDNA, Leipzig / / EDEKA, Landsberg / EDNA, Leipzig /

TARGET, West Jefferson / TARGET, TARGET, West Jefferson / TARGET, RialtoRialto

E. LECLERC, Colmar / EDEKA, E. LECLERC, Colmar / EDEKA, ZarrentinZarrentin

• The patented OPM / COM solutions is the most

successful automated storage and picking system

in the food retail market

• 24 OPM / COM projects in Europe and North

America

• Over 410 sold COMs

• Over 2 billion cases picked with COM since

implementation

• Over 3 million cases picked

with COM per day




WITRON – EDNA Project Overview

Central warehouse for production and

trade goods including small volume order

picking in Brehna

Temperature in order picking area: - 24° C

Temperature in packaging area: + 3° C

Number of customers being supplied: 858

Number of articles in OPM: 510

Number of COMs: 3

Storage locations in the tray warehouse: 30,240

Storage locations in the pallet warehouse: 9,600

Picked cases/day: 13,000

Picked cases/hour: 1,350

Volume per case: 32.7 liters

Volume output per hour: 44 m3

Total Invest: 19 Million Euro




Concept – Technical Details

Receiving

Unloading docks: 2

Infeed station Reception: 1

Infeed station Production: 1

HBW

Total pallet locations: 9,470

Stored pallets: 9,000

Stacker cranes: 4

OPM

Installed tray locations: 30,240

Stored cases: 38,700

COM Machines: 3

High-speed tray miniloads: 6

Depalletizers: 2

Stretch wrapper: 1

Dispatch

Loading docks: 5

Dispatch lanes: 2

7,555 m2




WITRON – EDNA Project Overview




Frozen Goods Logistics – what is required for a successful project realization?

III and highly available technologies

A reliable partner who takes over

overall responsibility

for all functionalities and project phases

from design to successful acceptance I..




� Foundation: 1971 by Dipl.-Ing. Walter Winkler

� CEO: Dipl.-Math. Helmut Prieschenk

� Employees worldwide: approx. 1,400 (as of 2011)

� Revenue worldwide: approx. 200 million Euros (as of 2011)

� Headquarters: Parkstein, Germany / Bavaria

� Company: Owner-operated family business / foundation model

WITRON – The “freezer” experts from the Upper Palatinate

Design + Realization + Service + Operation of cost-efficient logistics + picking systems

� Subsidiaries:

Germany, Rimpar

USA, Arlington Heights, Illinois

Canada, Toronto

Netherlands, Venray

UK, Stoke-on-Trent

Spain, Madrid

France, Strassbourg




Subsidiary FAS – Förder Anlagen Systeme GmbH

Software PLC

Mechanics

� Foundation: 1996 in Saarbruecken / 2007 in Parkstein

� Products: • Tote, tray and pallet conveyor systems • COM Case Order Machine

• Tote stacker cranes • CRS Coordinate Rack Shuttle

• Tote / tray stacker • Sequence Buffer

� Production Area: approx. 25.000 m²

Currently expansion for additional 30.000 m² production area

� Employees: > 120

� Focus: Mechanics systems for WITRON standard solutions like OPM, ETP, DPS




Circuit of Successful Project Work

Rough and detailed planning, efficiency studies,

comparison of options, simulation (WSS)

Acquisition of customer-related business processes,

data analysis and evaluation, conceptual design

Design of “tailor-made” support packages to guarantee high

cost-effectiveness and availability

Logistics Design

Project Realization

Integration Support

Customer Support

1.

2.

3.

4.

5.

Analysis

System responsibility

throughout all

project phasesGeneral Contractor project management, sub-supplier

management, IT / software and PLC systems, installation management

Professional ramp-up management, start-up of all system components,

employee training




Selected references - freezer

Europe12 x freezer systems

North America4 x freezer systems




Thank you very much for

your attention!

WITRON Logistik + Informatik GmbH

Neustaedter Str. 21

92711 Parkstein

www.witron.de

witron opm technology for the frozen goods...

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