Mapping Audit Reduces Facility Noise

Dematic has just launched its Noise Reduction portfolio worldwide, a comprehensive set of solutions to address loud work environments across supply chain facilities. The offering includes before and after 3D noise mapping audits throughout a facility, enhanced rollers, slats, and belt conveyors that can reduce noises at their source by up to 15 decibels.

“The well-being of our customers and their employees is a high priority that includes protecting hearing when working in loud environments like distribution centres,” says Andy Randles, senior director, Global Lifecycle Support. “By implementing this portfolio of technology, our customers can take the noise levels down in their facilities from a concert hall to a classroom chat. It’s a huge step forward in improving work environments.”

To diagnose noise levels, Dematic uses 3D noise mapping to conduct on-site testing at customer facilities that visually identifies acoustic hazards, similar to the way a heatmap identifies temperature hazards. Dematic then builds a noise model to simulate how upgrading equipment would reduce noise levels. The company recommends upgrades and installs quiet rollers, slats and conveyors as needed. Dematic conducts a second test after installation to demonstrate the difference before and after the upgrade was made.

“We’re proud to provide such a comprehensive noise reduction portfolio,” says Randles. “Reducing noise levels in facilities is not only meaningful for worker health and safety, but also to job satisfaction. We’ve heard from customers that morale and productivity among workers goes up when noise levels are lower.”

According to the National Institute for Occupational Safety and Health (NIOSH), approximately 22 million workers in the US are exposed to noise loud enough to damage their hearing each year. Similarly, studies in Europe have found up to 30 million workers are exposed to occupational noise that endangers their hearing. Results of research studies like these, underscore the importance of furthering technology and solutions that protect worker hearing and improve safety.

The new portfolio continues Dematic’s focus on reducing noise levels in customer facilities so workers can better communicate and hear safety sounds. In 2022, Dematic introduced new noise reduction features on its linear sorter that included quiet shoes, merge wedges and slider belts.

Dematic designs, builds, and supports intelligent automated solutions empowering and sustaining the future of commerce for its customers in manufacturing, warehousing, and distribution. With research and development engineering centres, manufacturing facilities, and service centres located in more than 35 countries, the Dematic global network of over 11,000 employees has helped achieve successful customer installations for some of the world’s leading brands. Headquartered in Atlanta, Dematic is a member of KION Group, one of the world’s leading suppliers of industrial trucks and supply chain solutions.

Enhanced Processes for Spanish 3PL Operator

Third-party logistics operator Factor 5 recently commissioned a goods-to-person solution featuring an AutoStore™ automated storage and picking system provided by intelligent automation solution provider Dematic. The solution enhances its order process for perfumes and cosmetics products with the aim of boosting sales and strengthening its ability to compete in the long term. The solution went live this past March at Factor 5’s Alovera site northeast of Madrid.

Headquartered in Spain’s mid-section in Guadalajara, with 2,000 employees and over 400,000 square meter of warehouse space, Factor 5 is one of Spain’s leading third-party logistics operators.

According to Maria de Jesús, the Supply Chain director at Factor 5, Dematic was selected for its flexibility, global reach and reliability. “We wanted an international technology partner who could offer us a selection of solutions that meet the needs of customers looking to transform their supply chains and looking for increasingly efficient and scalable logistics operations to reduce costs and accommodate growth of online sales. And we wanted a solid service partner who would be there for us to support our own growth projections for the coming years.”

Factor 5 opted for a modular automation solution from Dematic, which features a high-performance storage system that is easily scalable, has very low energy consumption and provides excellent inventory security. The solution significantly reduces the amount of space required for storage and improves order preparation process times. The project got underway in March 2022 and was completed in just under 12 months.

Dematic Software manages and runs the entire automated system. The AutoStore™ automated storage and picking system includes nearly 4,400 containers for storage and seven R5 robots for collecting and delivering the containers with the requested items to one of five workstations where operators collect the items to complete orders. The goods-to-person concept is anticipated to substantially increase productivity as Factor 5 employees no longer need to cover long distances to collect individual order items.

“Our goal has been twofold with this project. Of course, we wanted to deliver a robust solution to Factor 5 that meets their requirements from top to bottom, but we also wanted to establish a strong relationship with them that provides added value where they view Dematic as a reliable technology partner for the long term”, explains Sonia Bello, Sales Director at Dematic Iberia.

Santiago de Vicente, CEO at Factor 5, states, “We are convinced that the Dematic solution perfectly meets our business needs, and as we face an increasingly complex market, Dematic can provide advanced and structured technology solutions to support our company’s growth and development in the years to come.”

Dematic designs, builds, and supports intelligent automated solutions empowering and sustaining the future of commerce for its customers in manufacturing, warehousing, and distribution. With research and development engineering centres, manufacturing facilities, and service centres located in more than 35 countries, the Dematic global network of over 11,000 employees has helped achieve successful customer installations for some of the world’s leading brands. Headquartered in Atlanta, Dematic is a member of KION Group, one of the world’s leading suppliers of industrial trucks and supply chain solutions.

New Distribution Centre has Latest Automation

Ground was recently broken for a new distribution centre where Dematic is set to supply the latest warehouse automation technology to parent company KION Group at its site in Kahl am Main near Aschaffenburg, Germany.

When completed in roughly two years, brands within KION Group will use the facility for delivering spare parts across Europe. The goal is to ensure more efficient customer deliveries. Dematic is scheduled to install a highly dynamic Dematic Multishuttle® with 110,000 storage locations and 150 shuttles to handle automatic storage and retrieval. In addition, US-headquartered company is building a 6-aisle, scalable high-bay warehouse with a silo design and almost 24,000 pallet spaces. Fellow KION Group brand, Linde Material Handling, will supply several autonomous mobile robots (AMRs).

“This new, highly automated spare parts warehouse is a flagship project for both Dematic and the entire KION Group and a prime example of our combined strengths in terms of our own technologies within KION,” explains Andrea Campora, Senior Vice President at Dematic EMEA, adding, “Dematic and Linde plan to share the site when it is ready. It will result in a closer integration with employees from different areas benefiting from each other’s expertise.” While Dematic is a specialist in the Supply Chain Solutions (SCS) segment at KION, Linde has expertise in the Industrial Trucks & Services (ITS) segment.

In addition to more efficient processes, the new spare parts warehouse offers other benefits. “The logistics centre allows us to expand our production capacities, makes us less dependent on external supply chains, and lays the foundation for growing our business in German-speaking regions and beyond,” says Campora.

The new facility is also anticipated to create a near 100% spare parts availability. Dematic is expecting higher customer satisfaction through faster deliveries. Thanks to the environmentally friendly construction and a photovoltaic system, the CO2 savings also help to make the site as climate neutral as possible.

The new warehouse’s multishuttle is capable of handling different container type sizes to automatically store and retrieve goods. Items that are too large for totes and that cannot be stored in the multishuttle are packed onto pallets and stored in one of the six high-bay warehouse aisles. A special feature of the facility is that the multishuttle will be installed on a steel structure approximately five meters high. Picking workstations, packing stations, and other operational areas will be located under this massive platform. Smooth and automated material flow will be ensured by electric floor conveyors and modular conveyor systems from Dematic along with AMRs from Linde MH.

“The increased level of service allows the system to process orders that arrive by 4 pm on the same day,” Campora explains, adding, “These orders can then be in transit or already on-site the following day.”

The project once again underlines the close cooperation and comprehensive solution expertise under the umbrella of the KION Group. The ground-breaking ceremony took place at the end of February, and completion and joint move-in are projected for early 2025.

“Completion of this project is a milestone naturally internally for KION’s strategic goals, but the positive impact of this new facility will be felt by all of our customers and that is the way it should be – for the benefit of our customers,” sums up Campora.

Dematic designs, builds, and supports intelligent automated solutions empowering and sustaining the future of commerce for its customers in manufacturing, warehousing, and distribution. With research and development engineering centres, manufacturing facilities, and service centres located in more than 35 countries, the Dematic global network of over 11,000 employees has helped achieve approximately 8,000 worldwide customer installations for some of the world’s leading brands. Headquartered in Atlanta, Dematic is a member of KION Group, one of the world’s leading suppliers of industrial trucks and supply chain solutions.

Making Intralogistics Smart, Together

Using this slogan, the Hamburg-based intralogistics and automation specialist STILL will be exhibiting innovative industrial trucks live in action in practical automation processes at this year’s LogiMAT trade fair from April 25 to 27th in Stuttgart, in Hall 10 at Stands 10B40, 10B41 and 10B51. A unique feature to date is the presentation of an integrated automation solution together with the KION Group’s sister company DEMATIC. A collaboration with high innovation potential.

The lack of skilled workers, growing cost pressure and the increasing “race against time” are forcing companies to automate their production or logistics processes. “At STILL, we are registering a growing demand for automation solutions that can be implemented quickly and are scalable,” confirms Frank Müller, Senior Vice President STILL Brand Management. “Surveys we conducted have shown that in the next three years more than half of our customers would like to automate processes that are still managed manually today. Against this background, automation has long been a strategic cornerstone for the future of STILL.”

Realistic material flow

Just how automated flows of goods run optimally in practice will be demonstrated by the Hamburg automation professionals during this year’s LogiMAT. A typical material flow found in many industries will be simulated there: Pallets arrive at the warehouse by truck, an automated EXV iGo systems high lift pallet truck picks up the delivery from the truck unloading station and takes it to the contour control – a control device that is as smart as it is slim, works independently of conveyor technology and can therefore be freely positioned in the warehouse. Flawless pallets are also stored from there via an EXV iGo systems. If a customer order is placed, the high lift pallet truck removes the goods from storage and makes them available at a transfer station. Here, an ACH autonomous mobile robot (AMR) takes over the horizontal transport in the direction of the conveyor system in order to pass on the goods for repalletising and packing according to the customer’s order. What this automated material flow looks like can be seen at the neighbouring stand (Hall 10, Stand 10C41) of the group’s sister company Dematic (KION Group). “By working closely with Dematic, we leverage valuable synergies that benefit our customers. The jointly developed integrated automation solutions are unparalleled on the market,” states Frank Müller confidently.

STILL can rely on an enormous wealth of experience in process automation and also on the proven capabilities of the trucks. These are used in the automated flows of goods for precisely the tasks for which they were optimised. The high lift pallet trucks are responsible for the vertical storage and retrieval processes, while the autonomously operating mobile robots take over the horizontal transport of goods, for which they have proven to be swift load carriers. They are increasingly being used not only in production, but also in warehouse logistics, and are especially effective in confined spaces. With their compact design, they need barely half the space of a forklift truck when picking up and delivering the load. STILL offers this AMR in two versions: The entry-level ACH version uses QR code navigation to orientate itself along the floor and can be integrated cost-effectively into existing systems. It is the right choice wherever goods have to be transported along fixed and always consistent routes. For more complex applications, the new AXH is the right choice. It has a higher degree of autonomy and thus also copes well in mixed operation – both in collaborative interaction with other AGVs such as vertical order pickers or reach trucks, but also with manually controlled industrial trucks.

Two product lines as precision-fit answers to customer requirements

In addition to the automation scenario, STILL will present LogiMAT stand visitors for the first time with the two product lines that are precisely tailored to individual customer requirements: the “Xcellence-Line” and the “Classic-Line”. The new Classic-Line offers entry-level solutions with a focus on core functions: standardised, quickly available and at attractive prices. In this way, the intralogistics provider is reacting to the trend towards “concentrating on the essentials” and aims to be even more customer-oriented. These entry-level units are already configured and thus also quickly available. The Xcellence-Line offers the most advanced technology for demanding applications, highly variable and customisable. The centrepiece of this line will be the future RXE series: the next generation of electric forklift trucks. In addition, a number of innovations will also be on show in the field of warehouse technology, such as the IFOY-nominated EXH low lift pallet truck, with its completely newly developed tiller concept, or the EXH-SF 14-16C low lift pallet truck with foldable stand-on platform.

As a further innovation, STILL will present smart solutions in the field of energy management to the international trade audience in Stuttgart. From the latest Li-ion models to fuel cell vehicles with integrated fuel cell systems to intelligent charging management.

Dematic Expands UAE Operations

Dematic recently opened an office in Abu Dhabi to better serve its customers within the United Arab Emirates and the entire GCC region. The opening of the second office broadens the global leader of automated warehouse and distribution centre design and delivery in the UAE.

The new Abu Dhabi office location is in the Musaffah industrial district in the southwestern part of Abu Dhabi and is considered one of the most important economic areas within the UAE. Dematic’s office is in Mazyd Mall.

“The UAE has traditionally been a trade hub thanks to its central location as well as strong ports developed over the years as a key economic driver. As globalization has accelerated around the world, countries such as UAE have continued to evolve as major players in the international logistics supply chain. With the region continuously building its status as a global trade hub, it is essential for companies such as Dematic to have a solid footing in the GCC states,” explains Rainer Schmid, regional market leader for the Middle East.

Both office locations are overseen by the Dematic Sales team in Dubai of Mithun Perinchery, Head of Sales for the Middle East, Turkey & Africa and Thomas Rosenau, Installation and Customer Service.

“We are generally known in the region as the company Landmark Group selected to automate their massive and state-of-the-art O-mega distribution centre. This facility in Dubai’s Jebel Ali Free Zone (JAFZA) centrally consolidates inventory and directly supplies regional warehouses in other Gulf Cooperation Council countries as well as stores and consumers,” notes Perinchery, adding, “but our goal is to establish Dematic across the Middle East as the partner of choice for intralogistics automation and software. We leverage our global expertise with local delivery and that requires setting up local offices in the key markets.”

Perinchery and Rosenau themselves moved into a new office in 2021 in Dubai, which is located at the European Business Centre in Dubai Investments Park.

Rosenau, who has been with Dematic since 2006, has been based in Dubai since 2017. He began as site project manager for the Landmark project before taking the lead for installation, customer service activities and Managing Director in UAE.
Perinchery has been in the UAE for the past 15 years and joined Dematic in 2021. He gained broad experience managing intralogistics automation prior to his role at Dematic.

 

New Production Hub: Recipe for Increased Capacity

Dematic has announced completion of a significant project for Gousto, a UK leading recipe box provider, to create a new flagship automated fulfilment centre in Spalding, Lincolnshire. The new production hub, where Gousto’s recipe boxes are created and sent out for delivery, will increase the company’s capacity beyond the 5 million meals per month currently being delivered to homes across the UK.

To meet increased customer demand, Gousto initiated an investment programme designed to step up its capacity, including accelerating plans for multiple new fulfilment centres and creating an additional 1,000 jobs by 2022.

The Company’s second fulfilment centre in Lincolnshire is scheduled to be operational before the end of 2020. Funds from a recent funding round put the value of the business in excess of US$1 billion thus achieving it ‘Tech Unicorn’ status. This will bring forward the opening of a further two Dematic-designed automated facilities which will significantly increase Gousto’s production capacity by automating its fulfilment systems to improve efficiency and throughput.

Timo Boldt, CEO and Founder of Gousto, said: “The UK recipe box market has come of age in 2020, with the lockdown restrictions accelerating trends that were already firmly underway and new customers by the thousands being won over to the variety of meal choice and the convenience of high quality, fresh ingredients being delivered directly to their door.

“As our business continues to thrive and grow, it’s vitally important we have the infrastructure in place to meet rapidly rising levels of demand, whilst providing the best experience for our customers. Automation is at the heart of this strategy for Gousto. Being the only provider in this space with fully automated production facilities enables us to offer by far the most choice and at the lowest price point for our customers. This technology and our partnership with Dematic helps us cement our market leadership.”

Andy Blandford, Managing Director of Northern Europe at Dematic, said: “Gousto is one of the real success stories of the past few years — success that’s now been supercharged by the rise in popularity of recipe boxes.  At these high volumes, when menus and products change on a regular basis, it’s simply not possible to fulfil orders using manual solutions. Automation has provided Gousto with the answer, and they are reaping the rewards with over 100% year-on-year growth.”

All of the new fulfilment centres are powered by Gousto’s proprietary algorithms alongside Dematic’s automation technologies increasing  daily volumes, pick speed and accuracy, whilst reducing costs.

Following the completion of this latest fulfilment centre, plans are now being developed for a new, even larger automated facility. Intended to come online in 2022, this Dematic-designed project is expected to more than double Gousto’s capacity again.

Dematic also announced a new project win in Denmark this August for retailer Reitan Distribution

 

Coop Denmark Awards Multi-Million Euro Service Contract

Denmark’s largest retailer Coop has awarded a new service contract to Dematic. The work is to provide ongoing onsite support for warehouse automation systems at the retailer’s main distribution centre in Odense, Denmark.

The Coop service contract now covers not just Dematic’s own Multishuttle tote storage system at the 65,000 m2 distribution centre, but also the high-bay storage system and AutoStore installation. Dematic will provide all on-site support services. 26 employees are now based full-time at the Coop facility. The team is to carry out predictive, planned and reactive maintenance as well as gather data. They work closely with Coop’s own teams in order to continuously improve the facility’s automated systems to ensure maximum uptime and throughput.

Morten Boye, Process and Technical Manager at Coop Denmark, said: “The automation systems at our Odense facility are the engine room of our entire supply chain operation. Without it we couldn’t keep our 1,000 national retail outlets stocked or fulfil our growing volume of online orders. And as with engines, the systems need to be maintained well so it can work at maximum efficiency.

A logical choice

“A service contract for Coop cannot be a transactional relationship,” Morten added. “We need a partner who’s always-on and who is constantly looking for ways to make things better. Our idea partner makes incremental improvements to the technology itself. We want to work with someone to carry out predictive maintenance or gather new data sets to inform our fulfilment strategy in future. As that’s what we’ve had from Dematic since the takeover in 2013, it’s made extending our contract with them to cover our facility the logical choice.”

Andy Blandford, Managing Director of Dematic Northern Europe commented: “Our team at the Odense site has always been treated as a vital part of the Coop team. Our ideas are heard and often have led to significant improvements. It’s a real partnership that we’re very proud of. We are therefore thrilled to extend this new contract.”

Coop is Denmark’s largest retailer and is one of the country’s best known grocery brands. In 2010, the cooperative consolidated its slow-moving dry-food goods from several warehouses with around 100,000 m2 to a newly constructed  65,000 m2 facility at Odense.

Building on an existing automated 32,000 pallet high bay store, Dematic created a goods-to-person automated picking system. The system is capable of both handling slow-moving products and assembling store orders in totes for dispatch. The upgraded system occupies only 6,500 m2 of the facility while processing 50% of the volume.

A 16-person Dematic team has been working on-site at the Odense facility since January 2013. This has now expanded to 26 with the new contract.

 

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