It all started 86 years ago with a hydraulic lifting winch for loads up to 10 tons. Today, Weber-Hydraulik manufactures high-quality cylinders, power units, control blocks, valves, and a comprehensive range of workshop equipment at five locations. Kardex modernized the buffer warehouse for production supply.
Kardex modernized the two-aisle high-bay warehouse within three weeks. The project included replacing two storage and retrieval machines and upgrading the conveyor system with two transfer cars, five height-adjustable picking stations, and two weighing terminals. A customized material flow control system was also implemented.
After the renovation.
The buffer warehouse for production supply at the company headquarters in Güglingen had become outdated. The system, built by a third-party supplier, was mechanically worn. The entire process was to be completely redefined and made more efficient. Against this backdrop, the two-aisle automated high-bay warehouse was to be completely modernized. In addition, the conveyor technology was to be renewed and new ergonomic workstations implemented. A customized material flow control system with an individual concept completed the project requirements.
Tight timeframe
One of the particular challenges was the tight timeframe: "The extensive measures had to be completely completed within just three weeks," emphasizes Chris Gulyasch, project manager at Weber-Hydraulik.
As a first step, the Kardex Mlog team dismantled the third-party supplier's worn-out storage and retrieval machines after 30 years of operation. They were then removed using a crane via a roof hatch.
Previous checkpoint. Photos: Kardex / LogPR
The two new MSingle A units, equipped with walkways and automatic controls, then followed the same route in the opposite direction. Light curtains and a key-operated access system ensure a high level of system security. The exchange operation, carried out with utmost precision, was completed exactly according to the tight schedule.
In addition, Kardex installed an extra receiving dock, another distribution cart with a camera, and two additional picking lanes in the receiving area. The order picking department also benefited: Picking now takes place at five ergonomic, height-adjustable workstations with hydraulic scissor lift tables.
Space created
The new concept is equally noticeable at the two redesigned loading and unloading areas: The removal of the supervisor's cabin has created space for additional storage areas. Goods are placed to the side and picked up with a forklift. Now, eleven different load carriers can be stored without repalletizing – including Euro and steel flat pallets, various stacking containers, wire mesh boxes, and plastic system pallets.
The newly installed MFlow material flow computer now handles order and storage location management, while plant visualization is ensured by the Kardex MVisu software. All processes in the buffer warehouse are now completely transparent, and fault management has been significantly improved.
Checkpoint afterwards.
Kardex MFlow features interfaces to the subordinate control systems of the conveyors, vertical transfer units, and stacker cranes. The software also communicates with the on-site SAP warehouse management system. "Thanks to Kardex MFlow, the warehouse is no longer a black box for Weber-Hydraulik. Now it's always clearly visible where each load is located," explains Kardex project manager Martin Ewert.
