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to handle a very broad article range
with a vast number of small and micro
items. Buffer lines located in front of
the workstations allow the sequential
provision of the storage totes and at the
same time to work seamlessly with the
highly dynamic stacker cranes.
Ergonomic needs have been met.
“These requirements include the
provision of goods according to the
goods-to-person principle, as well as
totes being automatically inclined by 45
degrees, the ability to adjust the height
of the workstation by means of in-house-
developed floor slabs, and a significant
noise reduction at the workplace and in
the whole system area.
“Thanks to the completely automated
supply and removal process, the
totes no longer need to be lifted or
carried”, explains Josef Gallersdoerfer,
Authorized Signatory at Witron.
“Moreover, the picker can either sit
or stand and to use either a touch
screen or a foot pedal to confirm the
orders while he or she is working.”
The workstations’ design is bright
and visually appealing to provide a
comfortable work environment for
each employee. Each position has the
capability of processing up to ten orders
at the same time. A storage tote can
contain up to four different products at
the same time. The largely error-free
order picking is ensured through pick-
by-light displays and integrated area
scanners. An acoustic signal will inform
the employee in case there are any
picking errors. Every process step will
be outlined transparently by terminal
dialogues. The average picking speed
is 200 picks per workstation/h.
Skoda transports the totes of different
sizes and heights used in the new AS/
RS on trays.
The bottom of the tray carrier plate has
a flexible design able to transport one
or four totes at the same time. If the
OPS system identifies that a certain
number of empty totes is in the AS/RS
when handling trays with two or four
totes for example, these empty totes
will automatically be transported to
a consolidation point. Full and empty
totes are there separated mechanically.
Full totes will be merged onto trays of
two or four and returned automatically
to the AS/RS. Empty trays will also be
bundled automatically on to trays of two
or four and transported to the receiving
area, where they can be replenished.
The consolidation will immediately be
updated in the warehouse management
system. This process no longer requires
manual support. “This system-related
consolidation allows for a separation of
full and empty totes and, via software,
to optimally use the existing storage
capacities”, says Gallersdoerfer. “With
the compactness achieved in the system,
it is now possible to efficiently handle an
even broader assortment in the AS/RS.”
As part of an integrated and holistic
overall logistics concept, Škoda
and Witron have also successfully
implemented a new forklift guiding
system.
Currently, some 160 logistics
providers, operating in a three-shift
operation, are equipped with forklift
and hand-held terminals - further
expansion is planned. Moreover, ITM
can seamlessly be integrated into
Witron’s AS/RS, so that order totes can
be transported as a bundle directly to
the dispatch area after they have been
picked. Alternatively, empty totes
can be transported to the receiving
area. As a sub-system, ITM generally
communicates via open interface and
can either be connected to SAP or to
all other ERP systems. The connection
to customer-specific warehouse
management systems and WMS
systems is guaranteed. The paperless
handling of transport orders is done
according to the customer’s demand
via hand-held terminals, forklift truck
terminals, or pick-by-voice devices.
Škoda has plans for the future. Mladá
Boleslav is going to be strategically
expanded with an additional hall. Two
additional AS/RS aisles will be installed
in the short term; the ten older aisles
will then be refurbished and updated
to the latest Witron technology in the
long-run. “It is absolutely necessary to
consider the employees’ needs when
carrying out the planned expansions”,
says Jira. “Our ambition will be to
design the picking workstations as
modern and ergonomic as possible.”
56
Logistics Business Magazine | February 2016
AUTOMATION