Industry 4.0 has now arrived across the board in modern metal processing – naturally also in warehousing and sawing technology. Machines, systems, goods, and load carriers are digitally networked and communicate with each other. Intelligent sensor systems provide status information in real time.

It starts with storage: Instead of the previously widespread floor or cantilever storage, metalworking companies are increasingly turning to fully automated long goods storage systems. These software-controlled systems impress with higher storage density, fast access times, and inventory transparency. They also enable the implementation of storage strategies tailored to the needs of each company: Users can store individual bars, entire bundles, or open bundles manually or automatically, and transfer them between different storage areas – depending on the requirements.

Fig.: Kasto / A1

Sawing technology—often the first processing station after removal from storage—is also increasingly being organized unmanned. Sawing machines can be seamlessly connected to the raw material warehouse using manipulators and conveyor technology, and supplied with the required materials via them. The sawing process itself also runs autonomously if the machine is appropriately equipped. This creates highly integrated systems that are seamlessly integrated into a continuous material flow—the smart factory.

Kasto implements combined storage-sawing-robot systems for its customers, in which all storage, handling, sawing, marking, palletizing, and bundling processes are fully automated, from the storage of raw materials to the picking of the cut sections. Smooth communication is particularly important: Simply put, all components involved must speak the same language. This is made possible by integrated control systems and suitable interfaces. Kasto offers a modular Warehouse Management System (WMS) specifically tailored to the requirements of long goods and sheet metal storage. It maps all processes between goods receipt and shipping in a clear and transparent manner and ensures efficient control of the entire material flow – including the warehouse, connected conveyor technology, and processing machines with the associated material handling.

The software optimizes processes. For example, it makes the routes of storage and retrieval machines more efficient by avoiding empty runs and placing more frequently used items closer to storage and retrieval stations than those that are less frequently used. Other helpful features include the management of orders, batches, offcuts, and trimmings, continuous inventory, and the ability to flexibly apply various in-out strategies and picking principles. The comprehensive statistics and analysis tools monitor the utilization of both the entire system and individual components. This allows the full potential of intralogistics to be exploited: unnecessary travel routes or unnecessary waiting times are avoided, and potential changes can be simulated in advance and tested without risk.

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