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Month: November 2023

Autonomous Data Capture

Posted on by David Priestman

Stock-taking in a warehouse is a time-consuming, manual process. Until now. David Priestman visited a British supplier of a robotic alternative.

Real-time data, including inventory, enables structural visibility in logistics, which leads to better resource allocation, reduced downtime and improved customer service. Dexory’s robot (pictured) automated inventory management, providing instant, continuous data. It can scan a medium-sized distribution centre in two hours, whereas doing it manually could take months. It corrects WMS errors and provides a ‘digital twin’ of the facility with 3D mapping.

Dexory offer this on a subscription model – RaaS, or robots-as-a-service – with no capital investment required. The company’s target are tier 1 customers with multiple locations, including third party logistics (3PL) firms, often with shared-user facilities. Maersk and Schenker have both invested in Dexory and Maersk are also using the product. I visited the production and demonstration site in Wallingford, Oxfordshire to understand why the company is making such rapid progress.

Tatiana Kalinina, VP of Sales, told me that Dexory has grown from 17 staff last summer to a likely 100 by this Christmas. She describes the machine as an ‘autonomous data capture unit’. The new model (RE4) is silent, handles precarious routes well and fully navigates a 3D space. The stopping distance is amendable and it can move around obstacles. It features an emergency stop button, though Kalinina says that has never needed to be used.

At 3.25m high the RE4 extends to 12m and can thereby scan up to 13.5m in a warehouse. Future models will be even taller. It lights up in a pleasant way and can work through the night. On average there are 16 LiDAR (light detection and ranging) cameras on each robot but sometimes up to 20. The LiDARs scan and produces high-res photos. The bot utilises a wireless docking station (supplied by Wiferion) for charging and recognises when it needs to charge, with an 8-hour battery life. Customers can choose bespoke options (such as height), their own livery colours or ‘skin’ and give the bot a nickname. It is easy to see why the bots are popular with warehouse workers.

“3PLs can invest in our system knowing this helps them to win business,” Kalinina told me. “We test each machine here with the customer’s bar codes before shipping it out to their site,” she added. Quality assurance testing of the tower extensions and cables, for example, is done here in Wallingford before shipment, vertically, using specially-designed transport trailers. Training and final testing is then done at the customer’s site, with remote monitoring and diagnostics provided.

All the design is done at this centre, as well as 3D printing of various plastic and carbon-fibre parts. The cameras are bought in, as are the batteries. The base is made first, then the tower. The target is to produce one robot per day by next year, in order to meet demand, and Dexory is scaling-up to that level. The whole unit weighs 600kg. It can work in ambient temperatures and within chilled areas of DCs, anything above zero degrees as the cameras cannot operate in frozen environments.

Dexory View

The platform that the robots work on is called ‘Dexory View’ (see image). This provides web-based reports, data interpretation and visualisation. KPIs can be measured. “It provides the capability to optimize your warehouse,” Kalinina explained. “It’s a Digital Twin – a like-for-like copy of your DC. All the aisles and location numbers are inputted in the first week of installation.” Given installation is usually just a week, quicker than for AMRs or AGVs, there are low barriers to entry. “There’s very little we ask for from customers,” she informed. “We do all the mapping for them and build the optimal path through the DC.”

A 2D ‘birds eye’ view is provided, which is intuitive to use and has zoom functions. Red is used to highlight errors detected. Options include not scanning reserve stock or very slow-moving products on site. Customers can choose which items are scanned daily. Dexory View provides a summary of each scan: time taken, locations scanned, missing items, places occupied with the incorrect item, unreadable barcodes, wrong items, put-away accuracy, volumetrics and more. It truly is ‘big data’ in action.

Warehouse managers can therefore compare, on a daily basis, each metric and see the trends – for example replenishment and stock turnover. These statistics can then be compared across different warehouses operated by the customer for best practice targets. The 3D view shows every location, with each one clickable and showing a photo. This enables errors to be checked and escalated without physically visiting the aisle in question. Tasks can be allocated from these findings. A photo scan of the whole aisle is also provided.

“We eliminate manual, repetitive tasks,” Kalinina concluded, “and provide a single source of the truth, alongside WMS and ERP, because of the regularity of scans. The bigger the facility, the greater the benefits and efficiencies.”

Autonomous Data Capture

Posted on by David Priestman

Stock-taking in a warehouse is a time-consuming, manual process. Until now. David Priestman visited a British supplier of a robotic alternative.

Real-time data, including inventory, enables structural visibility in logistics, which leads to better resource allocation, reduced downtime and improved customer service. Dexory’s robot (pictured) automated inventory management, providing instant, continuous data. It can scan a medium-sized distribution centre in two hours, whereas doing it manually could take months. It corrects WMS errors and provides a ‘digital twin’ of the facility with 3D mapping.

Dexory offer this on a subscription model – RaaS, or robots-as-a-service – with no capital investment required. The company’s target are tier 1 customers with multiple locations, including third party logistics (3PL) firms, often with shared-user facilities. Maersk and Schenker have both invested in Dexory and Maersk are also using the product. I visited the production and demonstration site in Wallingford, Oxfordshire to understand why the company is making such rapid progress.

Tatiana Kalinina, VP of Sales, told me that Dexory has grown from 17 staff last summer to a likely 100 by this Christmas. She describes the machine as an ‘autonomous data capture unit’. The new model (RE4) is silent, handles precarious routes well and fully navigates a 3D space. The stopping distance is amendable and it can move around obstacles. It features an emergency stop button, though Kalinina says that has never needed to be used.

At 3.25m high the RE4 extends to 12m and can thereby scan up to 13.5m in a warehouse. Future models will be even taller. It lights up in a pleasant way and can work through the night. On average there are 16 LiDAR (light detection and ranging) cameras on each robot but sometimes up to 20. The LiDARs scan and produces high-res photos. The bot utilises a wireless docking station (supplied by Wiferion) for charging and recognises when it needs to charge, with an 8-hour battery life. Customers can choose bespoke options (such as height), their own livery colours or ‘skin’ and give the bot a nickname. It is easy to see why the bots are popular with warehouse workers.

“3PLs can invest in our system knowing this helps them to win business,” Kalinina told me. “We test each machine here with the customer’s bar codes before shipping it out to their site,” she added. Quality assurance testing of the tower extensions and cables, for example, is done here in Wallingford before shipment, vertically, using specially-designed transport trailers. Training and final testing is then done at the customer’s site, with remote monitoring and diagnostics provided.

All the design is done at this centre, as well as 3D printing of various plastic and carbon-fibre parts. The cameras are bought in, as are the batteries. The base is made first, then the tower. The target is to produce one robot per day by next year, in order to meet demand, and Dexory is scaling-up to that level. The whole unit weighs 600kg. It can work in ambient temperatures and within chilled areas of DCs, anything above zero degrees as the cameras cannot operate in frozen environments.

Dexory View

The platform that the robots work on is called ‘Dexory View’ (see image). This provides web-based reports, data interpretation and visualisation. KPIs can be measured. “It provides the capability to optimize your warehouse,” Kalinina explained. “It’s a Digital Twin – a like-for-like copy of your DC. All the aisles and location numbers are inputted in the first week of installation.” Given installation is usually just a week, quicker than for AMRs or AGVs, there are low barriers to entry. “There’s very little we ask for from customers,” she informed. “We do all the mapping for them and build the optimal path through the DC.”

A 2D ‘birds eye’ view is provided, which is intuitive to use and has zoom functions. Red is used to highlight errors detected. Options include not scanning reserve stock or very slow-moving products on site. Customers can choose which items are scanned daily. Dexory View provides a summary of each scan: time taken, locations scanned, missing items, places occupied with the incorrect item, unreadable barcodes, wrong items, put-away accuracy, volumetrics and more. It truly is ‘big data’ in action.

Warehouse managers can therefore compare, on a daily basis, each metric and see the trends – for example replenishment and stock turnover. These statistics can then be compared across different warehouses operated by the customer for best practice targets. The 3D view shows every location, with each one clickable and showing a photo. This enables errors to be checked and escalated without physically visiting the aisle in question. Tasks can be allocated from these findings. A photo scan of the whole aisle is also provided.

“We eliminate manual, repetitive tasks,” Kalinina concluded, “and provide a single source of the truth, alongside WMS and ERP, because of the regularity of scans. The bigger the facility, the greater the benefits and efficiencies.”

Side Loading – Efficiently and Safely

Posted on by David Priestman

KOOI® ReachForks, often known as telescopic forks, are a proprietary brand developed by Meijer Handling Solutions. These hydraulic forks are designed to extend and retract, allowing for more versatile operations, especially when dealing with the intricacies of truck loading and unloading.

The Traditional Method of Side Loading in Logistics

Side loading, i.e. loading or unloading goods from the side of a truck, is common method in the logistics industry. Why do many companies choose this method though, and what are the concerns when loading and unloading from the side? In this article, we delve deeper into the world of side loading.

The ease and flexibility of side loading

The main advantage of side unloading is that it allows direct access to the whole length of the cargo compartment, which means goods can be loaded and unloaded quickly in the most convenient order. This is particularly valuable when goods need to be delivered in a specific order or when handling products of varying shapes and sizes, which may not easily be loaded through the rear of the vehicle. There are some crucial considerations when loading and unloading trucks through the side.

Accessibility from both sides

In most cases, for the loading process to run efficiently, the forklift needs to be able to access the cargo compartment from both sides; otherwise, once one side has been loaded or unloaded, the truck has to be turned around completely to give the forklift access to the opposite side. When loading or unloading a truck from both sides, the operating area around the truck must be cordoned off to prevent accidents and potential injury to pedestrians. After all, a forklift can suddenly emerge unexpectedly from behind the truck, posing a danger to anyone who may be in the vicinity.
In summary, side loading offers significant advantages in terms of convenience and flexibility when handling goods. Nevertheless, as with any method, it is essential to evaluate the associated risks and implement appropriate safety measures.

Hydraulic Forks: The Future of Efficient and Safe Loading and Unloading

In the dynamic world of transport and logistics, efficiency and safety play a crucial role. Since Meijer Handling Solutions introduced hydraulic forks in 1980, significant progress has been made in the process of loading and unloading. With over 100,000 sets of ReachForks already in use, it is safe to say that telescopic forks have found their place in the logistics industry. It is therefore surprising that there are still companies that have still not fully embraced the benefits of this way of loading and unloading.

Features and benefits of hydraulic telescopic forks

– Functionality: Telescopic forks can be extended and retracted hydraulically from the operator’s seat. This eliminates the need for the forklift driver exit the cabin to fit or remove fork sleeves by hand.
– Space Optimization: The outer sleeves of these ReachForks can extend across the full width of the cargo compartment, eliminating the need for the forklift to load or unload the trailer from both sides.
– Safety Benefits: This functionality means you only have to open the curtain on one side of the truck. This increases safety because the forklift remains in constant view, thus reducing the potential for accidents.

– Space savings: Trucks can now be parked closer to walls, so the space previously reserved for forklift manoeuvres can now be used for additional storage.

Selecting the appropriate combination of forklift and reach forks is of paramount importance in terms of both maximum efficiency and safety. As the forks extend and the load moves away from the forklift, it is crucial that the forklift does not overbalance and tip forward. Fortunately, KOOI®ReachForks can be supplied directly to forklift manufacturers or authorized forklift dealers. These professionals will advise you on the optimum combination, considering factors such as pallet weight. For example, while a 3000 kg forklift may be perfect for handling a 1000kg pallet, handling two such pallets simultaneously requires a 4000kg forklift.

Hydraulic KOOI® ReachForks offer a blend of speed, efficiency and safety, making them an indispensable tool for companies committed to achieving operational excellence:
Almost ± 30% faster than traditional side loading, when handling one pallet at the time, meaning at least one extra trailer per hour can be loaded/unloaded.
Almost ± 65% faster than traditional side loading, when handling two pallets at the time, meaning at least five extra trailers per hour can be loaded/unloaded.
Improved safety as forklift remains in view. Increased internal storage capacity.

Side Loading – Efficiently and Safely

Posted on by David Priestman

KOOI® ReachForks, often known as telescopic forks, are a proprietary brand developed by Meijer Handling Solutions. These hydraulic forks are designed to extend and retract, allowing for more versatile operations, especially when dealing with the intricacies of truck loading and unloading.

The Traditional Method of Side Loading in Logistics

Side loading, i.e. loading or unloading goods from the side of a truck, is common method in the logistics industry. Why do many companies choose this method though, and what are the concerns when loading and unloading from the side? In this article, we delve deeper into the world of side loading.

The ease and flexibility of side loading

The main advantage of side unloading is that it allows direct access to the whole length of the cargo compartment, which means goods can be loaded and unloaded quickly in the most convenient order. This is particularly valuable when goods need to be delivered in a specific order or when handling products of varying shapes and sizes, which may not easily be loaded through the rear of the vehicle. There are some crucial considerations when loading and unloading trucks through the side.

Accessibility from both sides

In most cases, for the loading process to run efficiently, the forklift needs to be able to access the cargo compartment from both sides; otherwise, once one side has been loaded or unloaded, the truck has to be turned around completely to give the forklift access to the opposite side. When loading or unloading a truck from both sides, the operating area around the truck must be cordoned off to prevent accidents and potential injury to pedestrians. After all, a forklift can suddenly emerge unexpectedly from behind the truck, posing a danger to anyone who may be in the vicinity.
In summary, side loading offers significant advantages in terms of convenience and flexibility when handling goods. Nevertheless, as with any method, it is essential to evaluate the associated risks and implement appropriate safety measures.

Hydraulic Forks: The Future of Efficient and Safe Loading and Unloading

In the dynamic world of transport and logistics, efficiency and safety play a crucial role. Since Meijer Handling Solutions introduced hydraulic forks in 1980, significant progress has been made in the process of loading and unloading. With over 100,000 sets of ReachForks already in use, it is safe to say that telescopic forks have found their place in the logistics industry. It is therefore surprising that there are still companies that have still not fully embraced the benefits of this way of loading and unloading.

Features and benefits of hydraulic telescopic forks

– Functionality: Telescopic forks can be extended and retracted hydraulically from the operator’s seat. This eliminates the need for the forklift driver exit the cabin to fit or remove fork sleeves by hand.
– Space Optimization: The outer sleeves of these ReachForks can extend across the full width of the cargo compartment, eliminating the need for the forklift to load or unload the trailer from both sides.
– Safety Benefits: This functionality means you only have to open the curtain on one side of the truck. This increases safety because the forklift remains in constant view, thus reducing the potential for accidents.

– Space savings: Trucks can now be parked closer to walls, so the space previously reserved for forklift manoeuvres can now be used for additional storage.

Selecting the appropriate combination of forklift and reach forks is of paramount importance in terms of both maximum efficiency and safety. As the forks extend and the load moves away from the forklift, it is crucial that the forklift does not overbalance and tip forward. Fortunately, KOOI®ReachForks can be supplied directly to forklift manufacturers or authorized forklift dealers. These professionals will advise you on the optimum combination, considering factors such as pallet weight. For example, while a 3000 kg forklift may be perfect for handling a 1000kg pallet, handling two such pallets simultaneously requires a 4000kg forklift.

Hydraulic KOOI® ReachForks offer a blend of speed, efficiency and safety, making them an indispensable tool for companies committed to achieving operational excellence:
Almost ± 30% faster than traditional side loading, when handling one pallet at the time, meaning at least one extra trailer per hour can be loaded/unloaded.
Almost ± 65% faster than traditional side loading, when handling two pallets at the time, meaning at least five extra trailers per hour can be loaded/unloaded.
Improved safety as forklift remains in view. Increased internal storage capacity.

20 Years of OPM Automation

Posted on by David Priestman

The revolution in food retail logistics began in Parkstein in 2003. Today, the OPM system is the world’s most successful fully automated logistics and order picking system for cases. It all started with a cake lifter.

The story of WITRON’s Order Picking Machinery system (OPM) begins at Walter Winkler’s coffee table in Parkstein. The breakthrough came with a cake and a cake server from the WITRON founder. The COM – the heart of the OPM system was born. Just as a cake lifter glides under the piece of cake, the COM moves under the items to be picked and uses them to load pallets and roll containers for the food retailers’ stores fully automatically, product-gently, store-friendly, and without errors. “We have a factory for the production of store pallets,” says Frédéric Pinier-Rafer from E.LECLERC Socara proudly. The OPM system celebrates its 20th anniversary in 2023. Almost 100 OPM systems are in operation today, supplying more than 35,000 stores and 100 million consumers in North America, Europe, and Australia every day.

Helmut Prieschenk, CEO of WITRON, and Karl Högen, CEO of WITRON North America, agree that the OPM was a revolution for the food retail industry. “That was Walter Winkler’s masterpiece,” says Prieschenk. Högen remembers: “Back then, I was working in sales at the Logistikhof. When the solution was first presented to the company, I thought: What a brilliant idea. This is going to be great!”

Today, Prieschenk and Högen are primarily focused on the business development in the various WITRON sales regions and look back to the first projects. “The pilot customer and the impetus for the development of the OPM system came via the food retailer KROGER from the US.” But the Europeans quickly followed. The first OPM logistics centres in Europe were built for MERCADONA in Spain and EDEKA in Germany.

The initial situation is hardly any different to today. “For many retailers, issues such as lack of personnel and high staff fluctuation were already a major challenge in their conventional warehouses back then”, says Högen. “Not surprising,” according to Prieschenk. “Millions of tons of food were moved by human hands. Employees had to bend down, lift, and carry heavy loads. That is already challenging and no fun in the dry food sector – and even less so in the fresh and frozen food environment.”

The workplaces in the distribution centres became more attractive thanks to the OPM system. “The new machines were proudly presented to the relatives at the family’s day,” Högen remembers the first system that was implemented in Phoenix, Arizona. Customers needed 60 percent less staff in the warehouse and, thanks to the automated production of load carriers, transport costs were reduced by more than 10 percent, and the time required to put items away in the stores was also reduced by double-digits. “The pallet is built store-friendly – individually according to the layout of the respective store. It only needs to be handled once in the store. It can directly be used to replenish the shelves or is sent to the back room,” explains Högen. In addition, there is less food waste due to damaged goods during transportation or unpacking. Thanks to new packaging technologies in the OPM system, the store managers and their staff members also have to dispose of less wrapping. “The OPM solution is integrated end-to-end into the customer’s processes – economically, ecologically, and socially,” he adds.

“The decisive factor is not to have an idea for an innovation,” emphasizes Prieschenk, “but to successfully implement this idea in practical use. That is exactly WITRON’s strength. We get systems up and running! Regardless of the size and complexity of the task.” With OPM, it is now possible to pick more than 95 percent of the product scope of a full-range retailer (dry, fresh, and frozen) fully automatically and store-friendly in aisle sequence onto pallets or roll containers, largely without the need for personnel.

EDEKA was one of the first customers to use the OPM system. Thomas Kerkenhoff who was responsible for logistics at EDEKA Rhein-Ruhr-Stiftung back then, has a concrete opinion on this. “There is no competitor solution on the market that can handle more than 10,000 different items fully automatically as efficiently as the WITRON system.” The manager is sure: “In order to operate a facility successfully and economically in the long-term, you need a particularly good team both at your logistics partner and on site that is constantly working on the enhancement of the mechanical components and the software. But this only works if you also have a partner who has already implemented a large number of systems in the industry worldwide, and thus has extensive experience, expertise, and references. If I invest money, then the system must be able to map my business model also in 25 years’ time – but at the same time it must also be able to flexibly adapt to new basic conditions and business processes. That is what I expect as a customer.” And this is what the OPM system is able to achieve – now in its fifth generation.

“Our systems grow with the customer. The challenge in a project is that we receive figures at the beginning of the project design phase that can change again during the implementation phase. And when markets change, the situation is often completely different.” For example, we had to quickly integrate efficient e-commerce processes for customers in the logistics centres that were originally designed purely for store delivery. The number of items changes, the volume varies, the order lines adapt, and more distribution channels are added. “We always have the goal in mind, primarily a high level of customer service, see logistics from the end customer’s perspective in the store or at home, and analyse developments”, explains Prieschenk, who has the advantage that WITRON supplies markets worldwide with its solutions, knows the processes in food retail down to the last detail, and recognizes developments on other continents faster than others.

High availability thanks to solid mechanics

The success of the OPM system is also based on the system’s design. “Mechanics has always been simple and thus solid, hardly prone to errors, and easy to maintain. The result is high system availability, 24/7. The software, the stacking algorithm takes care of the complexity”, emphasizes Helmut Prieschenk. Word spread quickly in the industry. Matt Swindells from Coles and his team travelled from Australia to the USA and Europe, saw various systems and his comment was: “This is like Tetris on steroids.” He then ordered the OPM system for his company’s sites in Brisbane and Sydney. More than 2,000 see freight containers made their way to down under. The WITRON staff travelled ahead by plane.

However, WITRON is not only responsible for the technology, but also ensures a permanently high availability of the system with well-trained personnel. “This has opened up a completely new business model for us. More than 4,000 staff members are currently working for us in the areas of service, maintenance, and system operation on site at our customers’ distribution centres”, says Prieschenk. For WITRON, service means that the customers can concentrate on their core business thanks to our technicians. WITRON’s successful OnSite team model was born at SPAR in Wels in 1998. The highly dynamic processes in an automated logistics centre demanded new answers from WITRON at that time. Back then, six technicians took care of the system. In the meantime, the facility has grown many times over in terms of footprint and throughput – and with it the service team. Today, there are 120 staff members working in multiple shifts ensuring smooth processes with regard to mechanics and IT – automation creates attractive workplaces. “It is not the number of employees in an on-site team that is decisive, but rather their extensive skills, their great commitment, as well as the scope of tasks, for which the WITRON experts take responsibility”, explains Prieschenk.

Current challenge: Intelligent networks

And WITRON is not running out of work. Customers want to build new facilities, but also realize brownfield projects with the OPM system. The OPM system works economically and highly efficiently in the dry, fresh, and frozen food sector – regardless of whether it is a new or existing building. But there are new tasks for the developers at WITRON. The story of the OPM system continues to be told, they say in Parkstein. The requirements for intra-logistics have changed and the OPM system has mastered the market changes – from pure store supply to omni-channel centres.

“We have solved the issue of automated piece and case picking, optimized flow-through logistics centres, implemented ugly items into the automated process, and are now continuing to think one step further – beyond consolidation”, promises Högen. Intelligent networks are the actual challenge. Now, not only the logistics centres, but the entire supply chains of the customers are to become efficient.” Our goal is to integrate all horizontal and vertical players of an omni-channel network: suppliers, logistics centre, transportation. This also includes the different distribution channels: store, home delivery, click & collect, drives. It is therefore important to create an efficient end-to-end retail platform, where silos are avoided, where all hubs permanently communicate with and optimize each other,” concludes Prieschenk, looking into the future. “WITRON’s success is a combination of our corporate culture, technical expertise, and domain knowledge, the two managers agree. Walter Winkler would say: We simply know our way around.”

20 Years of OPM Automation

Posted on by David Priestman

The revolution in food retail logistics began in Parkstein in 2003. Today, the OPM system is the world’s most successful fully automated logistics and order picking system for cases. It all started with a cake lifter.

The story of WITRON’s Order Picking Machinery system (OPM) begins at Walter Winkler’s coffee table in Parkstein. The breakthrough came with a cake and a cake server from the WITRON founder. The COM – the heart of the OPM system was born. Just as a cake lifter glides under the piece of cake, the COM moves under the items to be picked and uses them to load pallets and roll containers for the food retailers’ stores fully automatically, product-gently, store-friendly, and without errors. “We have a factory for the production of store pallets,” says Frédéric Pinier-Rafer from E.LECLERC Socara proudly. The OPM system celebrates its 20th anniversary in 2023. Almost 100 OPM systems are in operation today, supplying more than 35,000 stores and 100 million consumers in North America, Europe, and Australia every day.

Helmut Prieschenk, CEO of WITRON, and Karl Högen, CEO of WITRON North America, agree that the OPM was a revolution for the food retail industry. “That was Walter Winkler’s masterpiece,” says Prieschenk. Högen remembers: “Back then, I was working in sales at the Logistikhof. When the solution was first presented to the company, I thought: What a brilliant idea. This is going to be great!”

Today, Prieschenk and Högen are primarily focused on the business development in the various WITRON sales regions and look back to the first projects. “The pilot customer and the impetus for the development of the OPM system came via the food retailer KROGER from the US.” But the Europeans quickly followed. The first OPM logistics centres in Europe were built for MERCADONA in Spain and EDEKA in Germany.

The initial situation is hardly any different to today. “For many retailers, issues such as lack of personnel and high staff fluctuation were already a major challenge in their conventional warehouses back then”, says Högen. “Not surprising,” according to Prieschenk. “Millions of tons of food were moved by human hands. Employees had to bend down, lift, and carry heavy loads. That is already challenging and no fun in the dry food sector – and even less so in the fresh and frozen food environment.”

The workplaces in the distribution centres became more attractive thanks to the OPM system. “The new machines were proudly presented to the relatives at the family’s day,” Högen remembers the first system that was implemented in Phoenix, Arizona. Customers needed 60 percent less staff in the warehouse and, thanks to the automated production of load carriers, transport costs were reduced by more than 10 percent, and the time required to put items away in the stores was also reduced by double-digits. “The pallet is built store-friendly – individually according to the layout of the respective store. It only needs to be handled once in the store. It can directly be used to replenish the shelves or is sent to the back room,” explains Högen. In addition, there is less food waste due to damaged goods during transportation or unpacking. Thanks to new packaging technologies in the OPM system, the store managers and their staff members also have to dispose of less wrapping. “The OPM solution is integrated end-to-end into the customer’s processes – economically, ecologically, and socially,” he adds.

“The decisive factor is not to have an idea for an innovation,” emphasizes Prieschenk, “but to successfully implement this idea in practical use. That is exactly WITRON’s strength. We get systems up and running! Regardless of the size and complexity of the task.” With OPM, it is now possible to pick more than 95 percent of the product scope of a full-range retailer (dry, fresh, and frozen) fully automatically and store-friendly in aisle sequence onto pallets or roll containers, largely without the need for personnel.

EDEKA was one of the first customers to use the OPM system. Thomas Kerkenhoff who was responsible for logistics at EDEKA Rhein-Ruhr-Stiftung back then, has a concrete opinion on this. “There is no competitor solution on the market that can handle more than 10,000 different items fully automatically as efficiently as the WITRON system.” The manager is sure: “In order to operate a facility successfully and economically in the long-term, you need a particularly good team both at your logistics partner and on site that is constantly working on the enhancement of the mechanical components and the software. But this only works if you also have a partner who has already implemented a large number of systems in the industry worldwide, and thus has extensive experience, expertise, and references. If I invest money, then the system must be able to map my business model also in 25 years’ time – but at the same time it must also be able to flexibly adapt to new basic conditions and business processes. That is what I expect as a customer.” And this is what the OPM system is able to achieve – now in its fifth generation.

“Our systems grow with the customer. The challenge in a project is that we receive figures at the beginning of the project design phase that can change again during the implementation phase. And when markets change, the situation is often completely different.” For example, we had to quickly integrate efficient e-commerce processes for customers in the logistics centres that were originally designed purely for store delivery. The number of items changes, the volume varies, the order lines adapt, and more distribution channels are added. “We always have the goal in mind, primarily a high level of customer service, see logistics from the end customer’s perspective in the store or at home, and analyse developments”, explains Prieschenk, who has the advantage that WITRON supplies markets worldwide with its solutions, knows the processes in food retail down to the last detail, and recognizes developments on other continents faster than others.

High availability thanks to solid mechanics

The success of the OPM system is also based on the system’s design. “Mechanics has always been simple and thus solid, hardly prone to errors, and easy to maintain. The result is high system availability, 24/7. The software, the stacking algorithm takes care of the complexity”, emphasizes Helmut Prieschenk. Word spread quickly in the industry. Matt Swindells from Coles and his team travelled from Australia to the USA and Europe, saw various systems and his comment was: “This is like Tetris on steroids.” He then ordered the OPM system for his company’s sites in Brisbane and Sydney. More than 2,000 see freight containers made their way to down under. The WITRON staff travelled ahead by plane.

However, WITRON is not only responsible for the technology, but also ensures a permanently high availability of the system with well-trained personnel. “This has opened up a completely new business model for us. More than 4,000 staff members are currently working for us in the areas of service, maintenance, and system operation on site at our customers’ distribution centres”, says Prieschenk. For WITRON, service means that the customers can concentrate on their core business thanks to our technicians. WITRON’s successful OnSite team model was born at SPAR in Wels in 1998. The highly dynamic processes in an automated logistics centre demanded new answers from WITRON at that time. Back then, six technicians took care of the system. In the meantime, the facility has grown many times over in terms of footprint and throughput – and with it the service team. Today, there are 120 staff members working in multiple shifts ensuring smooth processes with regard to mechanics and IT – automation creates attractive workplaces. “It is not the number of employees in an on-site team that is decisive, but rather their extensive skills, their great commitment, as well as the scope of tasks, for which the WITRON experts take responsibility”, explains Prieschenk.

Current challenge: Intelligent networks

And WITRON is not running out of work. Customers want to build new facilities, but also realize brownfield projects with the OPM system. The OPM system works economically and highly efficiently in the dry, fresh, and frozen food sector – regardless of whether it is a new or existing building. But there are new tasks for the developers at WITRON. The story of the OPM system continues to be told, they say in Parkstein. The requirements for intra-logistics have changed and the OPM system has mastered the market changes – from pure store supply to omni-channel centres.

“We have solved the issue of automated piece and case picking, optimized flow-through logistics centres, implemented ugly items into the automated process, and are now continuing to think one step further – beyond consolidation”, promises Högen. Intelligent networks are the actual challenge. Now, not only the logistics centres, but the entire supply chains of the customers are to become efficient.” Our goal is to integrate all horizontal and vertical players of an omni-channel network: suppliers, logistics centre, transportation. This also includes the different distribution channels: store, home delivery, click & collect, drives. It is therefore important to create an efficient end-to-end retail platform, where silos are avoided, where all hubs permanently communicate with and optimize each other,” concludes Prieschenk, looking into the future. “WITRON’s success is a combination of our corporate culture, technical expertise, and domain knowledge, the two managers agree. Walter Winkler would say: We simply know our way around.”

Intelligent Sorting for Tunisian Post

Posted on by David Priestman

In Africa, e-commerce revenues are expected to exceed $46 billion in 2025, up from $28 billion in 2021, and 500 million online shoppers in 2025, up from 350 million in 2022, according to the latest study by consulting firm TechCabal Insights. Launched in 2016 by the Universal Postal Union (UPU), the Ecom@Africa project aims to develop intra-African and international e-commerce through the postal network in each of the five major African regions. The objective is to facilitate and accelerate the e-commerce activities of artisans, microenterprises, and small and medium-sized enterprises in this geographical area, enabling them to access local and international markets.

There are many challenges to overcome for the signatory African countries, from implementing a virtual e-commerce platform to designing a parcel receiving and sending logistics platform, as well as establishing a local distribution network and harmonizing practices. Among the first countries to experiment with this initiative, Tunisia aims to become the e-commerce hub for the North African region, according to an ambitious IT and logistics project roadmap. In this context, the Tunisian Post, a member of the UPU since 1878, has selected ISITEC International’s intelligent incoming and outgoing parcel sorting solution to equip its international e-commerce logistics platform, Ecom@Africa, through a tender process. Located on the outskirts of Tunis-Carthage Airport, it will be operational in January 2024.

Automating, ensuring reliability, and accelerating parcel sorting

Facing the decline of traditional postal services, the Tunisian Post aspires to seize the opportunities offered by the unprecedented growth of e-commerce, positioning itself as a key player in the management and optimization of associated services and logistics flows. It is currently establishing a state-of-the-art international logistics platform, Ecom@Africa, to optimize the processing of incoming and outgoing e-commerce parcels, as part of the UPU’s regional pilot program for the development of trade exchanges in Africa. To handle a growing volume of parcels, driven by e-commerce growth, the Tunisian Post aims to implement an automated sorting solution in 2022 to enhance operational efficiency, reliability, and agility, while reducing labor costs and human error.

This new equipment must address various challenges: automating, ensuring reliability, and optimizing the parcel sorting process to reduce processing and, consequently, delivery times; easily handling peak periods such as year-end holidays and Ramadan; providing seamless parcel traceability at every stage, ensuring transparency and customer satisfaction; and guaranteeing flexibility in sorting parcels of all sizes and shapes.

Sami Inoubli, PMO of the Ecom@Africa program at the Tunisian Post, summarizes: “The installation of an automated parcel sorting machine aims primarily to improve efficiency, reduce costs, increase sorting accuracy, and better manage capacity to cope with the exponential growth in parcel volume associated with the rise of e-commerce.”

As Inoubli, PMO of the Ecom@Africa program, reveals: “In our tender, we focused on identifying the key competencies required to find a company capable of providing us with a truly tailor-made solution that can be easily integrated into our IT systems, technical expertise, and maintenance and support services.” Ten criteria were defined: the capability to design and manufacture customized solutions that meet specific parcel sorting requirements (postal IT, size, shape, and volume of parcels), engineering capacity ensuring equipment quality, reliability, and durability, deployment of advanced automation technologies (computer vision, barcodes), and control software, integration with the existing postal information system, responsive maintenance and support, employee training, compliance with applicable standards and regulations, references, and a track record.

As an expert in optimizing postal and logistics flows worldwide, the French company ISITEC International stood out and won the tender from the Tunisian Post in December 2021. Inoubli adds, “In the context of our public procurement tender, the choice of ISITEC International was based on the total cost of ownership (TCO) of their intelligent parcel sorting solution. It is important, in our view, to evaluate a solution based on its total cost of ownership over its entire lifespan, from purchase and operation costs to maintenance and upgrades.”

Moreover, numerous strengths of ISITEC International’s proposal confirmed the Tunisian Post’s choice: performance, customization and scalability of the equipment, easy integration with existing IT and logistics systems, availability of technical support and after-sales service. The collaboration started in January 2022.

Inoubli said, “Our project requires close communication and careful planning with ISITEC International’s team to ensure that our equipment meets our needs and operates optimally.” Among the highlights of the collaboration with ISITEC International are the functional analysis stage, where the teams from ISITEC International and the Tunisian Post worked together to design and customize the parcel sorting machine according to specific needs, technical adaptations imposed by the facility’s area, options for customized sorting, and integration with existing systems. The installation, commissioning, and real-world testing of the ISITEC International solution were completed in September 2023.

Once the Ecom@Africa Hub becomes operational in 2024, ISITEC International’s intelligent sorting solution is expected to provide the Tunisian Post with greater operational efficiency through swift and precise sorting, ensuring high-quality service. The automation of parcel sorting is also expected to reduce labor costs, minimize sorting errors, and consequently reduce costs related to returns and re-shipments. ISITEC International’s solution will also significantly contribute to rigorous traceability. The equipment allows for precise tracking of parcel locations at every stage of processing within the Ecom@Africa e-commerce logistics platform.

In the coming months, the Tunisian Post will undertake a key step in its Ecom@Africa roadmap, the design and implementation of an Integrated Logistics Centre, which will cover all logistics aspects of national e-commerce, including inventory management, order preparation, and returns management. Once again, storage, automated sorting, and order preparation systems will be necessary.

Inoubli concludes: “Based on the quality of the relationship established, from contract signing to provisional acceptance, and including functional analysis, we have a partnership with ISITEC International rather than a customer-supplier relationship. In this partnership, we aspire to work together to optimize parcel sorting efficiency and achieve our goals. This necessarily involves close communication, faultless technical support, and regular equipment updates by ISITEC International.” The collaboration between the Tunisian Post and ISITEC International will span seven years, with two years of warranty period and five years under the maintenance contract.

Intelligent Sorting for Tunisian Post

Posted on by Keith McKinley

In Africa, e-commerce revenues are expected to exceed $46 billion in 2025, up from $28 billion in 2021, and 500 million online shoppers in 2025, up from 350 million in 2022, according to the latest study by consulting firm TechCabal Insights. Launched in 2016 by the Universal Postal Union (UPU), the Ecom@Africa project aims to develop intra-African and international e-commerce through the postal network in each of the five major African regions. The objective is to facilitate and accelerate the e-commerce activities of artisans, microenterprises, and small and medium-sized enterprises in this geographical area, enabling them to access local and international markets.

There are many challenges to overcome for the signatory African countries, from implementing a virtual e-commerce platform to designing a parcel receiving and sending logistics platform, as well as establishing a local distribution network and harmonizing practices. Among the first countries to experiment with this initiative, Tunisia aims to become the e-commerce hub for the North African region, according to an ambitious IT and logistics project roadmap. In this context, the Tunisian Post, a member of the UPU since 1878, has selected ISITEC International’s intelligent incoming and outgoing parcel sorting solution to equip its international e-commerce logistics platform, Ecom@Africa, through a tender process. Located on the outskirts of Tunis-Carthage Airport, it will be operational in January 2024.

Automating, ensuring reliability, and accelerating parcel sorting

Facing the decline of traditional postal services, the Tunisian Post aspires to seize the opportunities offered by the unprecedented growth of e-commerce, positioning itself as a key player in the management and optimization of associated services and logistics flows. It is currently establishing a state-of-the-art international logistics platform, Ecom@Africa, to optimize the processing of incoming and outgoing e-commerce parcels, as part of the UPU’s regional pilot program for the development of trade exchanges in Africa. To handle a growing volume of parcels, driven by e-commerce growth, the Tunisian Post aims to implement an automated sorting solution in 2022 to enhance operational efficiency, reliability, and agility, while reducing labor costs and human error.

This new equipment must address various challenges: automating, ensuring reliability, and optimizing the parcel sorting process to reduce processing and, consequently, delivery times; easily handling peak periods such as year-end holidays and Ramadan; providing seamless parcel traceability at every stage, ensuring transparency and customer satisfaction; and guaranteeing flexibility in sorting parcels of all sizes and shapes.

Sami Inoubli, PMO of the Ecom@Africa program at the Tunisian Post, summarizes: “The installation of an automated parcel sorting machine aims primarily to improve efficiency, reduce costs, increase sorting accuracy, and better manage capacity to cope with the exponential growth in parcel volume associated with the rise of e-commerce.”

As Inoubli, PMO of the Ecom@Africa program, reveals: “In our tender, we focused on identifying the key competencies required to find a company capable of providing us with a truly tailor-made solution that can be easily integrated into our IT systems, technical expertise, and maintenance and support services.” Ten criteria were defined: the capability to design and manufacture customized solutions that meet specific parcel sorting requirements (postal IT, size, shape, and volume of parcels), engineering capacity ensuring equipment quality, reliability, and durability, deployment of advanced automation technologies (computer vision, barcodes), and control software, integration with the existing postal information system, responsive maintenance and support, employee training, compliance with applicable standards and regulations, references, and a track record.

As an expert in optimizing postal and logistics flows worldwide, the French company ISITEC International stood out and won the tender from the Tunisian Post in December 2021. Inoubli adds, “In the context of our public procurement tender, the choice of ISITEC International was based on the total cost of ownership (TCO) of their intelligent parcel sorting solution. It is important, in our view, to evaluate a solution based on its total cost of ownership over its entire lifespan, from purchase and operation costs to maintenance and upgrades.”

Moreover, numerous strengths of ISITEC International’s proposal confirmed the Tunisian Post’s choice: performance, customization and scalability of the equipment, easy integration with existing IT and logistics systems, availability of technical support and after-sales service. The collaboration started in January 2022.

Inoubli said, “Our project requires close communication and careful planning with ISITEC International’s team to ensure that our equipment meets our needs and operates optimally.” Among the highlights of the collaboration with ISITEC International are the functional analysis stage, where the teams from ISITEC International and the Tunisian Post worked together to design and customize the parcel sorting machine according to specific needs, technical adaptations imposed by the facility’s area, options for customized sorting, and integration with existing systems. The installation, commissioning, and real-world testing of the ISITEC International solution were completed in September 2023.

Once the Ecom@Africa Hub becomes operational in 2024, ISITEC International’s intelligent sorting solution is expected to provide the Tunisian Post with greater operational efficiency through swift and precise sorting, ensuring high-quality service. The automation of parcel sorting is also expected to reduce labor costs, minimize sorting errors, and consequently reduce costs related to returns and re-shipments. ISITEC International’s solution will also significantly contribute to rigorous traceability. The equipment allows for precise tracking of parcel locations at every stage of processing within the Ecom@Africa e-commerce logistics platform.

In the coming months, the Tunisian Post will undertake a key step in its Ecom@Africa roadmap, the design and implementation of an Integrated Logistics Centre, which will cover all logistics aspects of national e-commerce, including inventory management, order preparation, and returns management. Once again, storage, automated sorting, and order preparation systems will be necessary.

Inoubli concludes: “Based on the quality of the relationship established, from contract signing to provisional acceptance, and including functional analysis, we have a partnership with ISITEC International rather than a customer-supplier relationship. In this partnership, we aspire to work together to optimize parcel sorting efficiency and achieve our goals. This necessarily involves close communication, faultless technical support, and regular equipment updates by ISITEC International.” The collaboration between the Tunisian Post and ISITEC International will span seven years, with two years of warranty period and five years under the maintenance contract.

Sustainability Strategy with Climate Tech

Posted on by David Priestman

Nippon Express Europe GmbH (NX Europe), a group company of the global Japanese logistics service provider Nippon Express Holdings, is set to realize the achievement of its sustainability goals in collaboration with the Climate Tech start-up, Cozero, based in Berlin.

In NX Group’s pursuit of reducing its CO₂ emissions by 50 percent by 2030 as compared to 2013 (Scope1,2), the parent company, Nippon Express Holdings Inc., submitted a letter of commitment to obtain Science Based Targets (SBT) certification in May 2023.

The collaboration between NX Europe and Cozero stemmed from Cozero’s comprehensive, transparent, and agile end-to-end solution that holistically considers both logistical and non-logistical emissions, which supports the forecasting and planning of decarbonization efforts.

Within a few weeks, Cozero’s Climate Action Platform was implemented at 30 European locations of the company for reporting Scope-1, Scope-2, and Scope-3 emissions. As a result, NX Europe is now able to implement customized local reduction strategies in alignment with SBT.

Climate Tech

Olaf Zimmlinghaus, Executive Director – General Affairs and Finance EMEA at NX Europe, stated, “Achieving our sustainability goals to combat climate change holds a special place within the NX Group. Our well-defined sustainability goals are not only deeply embedded in our operations but also subject to continuous monitoring of success. The data-driven solution provided by Cozero enables us to implement sustainability transformation into our corporate planning.”

Helen Tacke, Co-founder and CEO of Cozero GmbH, commented, “The NX Group is an exceptional example of the integration of financial and sustainability performances. Recognizing that corporate strategy and sustainability must walk hand in hand is pivotal for transformative success. We are proud to be able to contribute with data insights and measures through our software solution to support this synergy. “

Sustainability Strategy with Climate Tech

Posted on by David Priestman

Nippon Express Europe GmbH (NX Europe), a group company of the global Japanese logistics service provider Nippon Express Holdings, is set to realize the achievement of its sustainability goals in collaboration with the Climate Tech start-up, Cozero, based in Berlin.

In NX Group’s pursuit of reducing its CO₂ emissions by 50 percent by 2030 as compared to 2013 (Scope1,2), the parent company, Nippon Express Holdings Inc., submitted a letter of commitment to obtain Science Based Targets (SBT) certification in May 2023.

The collaboration between NX Europe and Cozero stemmed from Cozero’s comprehensive, transparent, and agile end-to-end solution that holistically considers both logistical and non-logistical emissions, which supports the forecasting and planning of decarbonization efforts.

Within a few weeks, Cozero’s Climate Action Platform was implemented at 30 European locations of the company for reporting Scope-1, Scope-2, and Scope-3 emissions. As a result, NX Europe is now able to implement customized local reduction strategies in alignment with SBT.

Climate Tech

Olaf Zimmlinghaus, Executive Director – General Affairs and Finance EMEA at NX Europe, stated, “Achieving our sustainability goals to combat climate change holds a special place within the NX Group. Our well-defined sustainability goals are not only deeply embedded in our operations but also subject to continuous monitoring of success. The data-driven solution provided by Cozero enables us to implement sustainability transformation into our corporate planning.”

Helen Tacke, Co-founder and CEO of Cozero GmbH, commented, “The NX Group is an exceptional example of the integration of financial and sustainability performances. Recognizing that corporate strategy and sustainability must walk hand in hand is pivotal for transformative success. We are proud to be able to contribute with data insights and measures through our software solution to support this synergy. “

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