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Tag: Kardex

Mahle Achieves Operational Efficiency with Cube Storage

Posted on by David Priestman

Having witnessed a trend towards more small package orders and less frequent large stock pallet orders, MAHLE Aftermarket selected a highly efficient AutoStore empowered by Kardex robotic cube storage system to increase capacity and throughput.

The global parts and solutions provider to the independent aftermarket was also experiencing storage capacity constraints at its distribution centre in Olive Branch, Mississippi. MAHLE looked for a high-density storage solution that would enable it to adapt to the shift in customer order profiles and is scalable for future growth. Having examined a range of options, the company invested in the AutoStore empowered by Kardex solution. The project has been hailed a success by MAHLE, helping the company store more products in less space and ship small orders more efficiently.

MAHLE chose Kardex to implement the intelligent goods-to-person automated storage and retrieval system (ASRS) tailored to MAHLE Aftermarket’s material flow, with market-leading inventory storage density and processing. The complete AutoStore solution at the Mississippi facility comprises 42,000 bins, 7 ports and 18 robots, in addition to a connected conveyor solution with 18 gravity lanes used for consolidation.

Designed and planned by Kardex, the AutoStore solution was built and commissioned on schedule and ramped up quickly and smoothly. Kardex FulfillX maximizes the capabilities of AutoStore robotic cube systems to optimize resources and processes, delivering the fastest order fulfilment solution per square foot on the market, increasing storage capacity by up to 4 times and enhancing performance by up to 10 times compared with traditional methods, without additional workforce.

Density, scalability and hands-on support

MAHLE Aftermarket has hailed the support Kardex provided throughout the project. Lorraine Hinderer, MAHLE Aftermarket Head of Business Innovation and Excellence, says, “One of the reasons we chose Kardex is because compared to the other integrators they were able to provide an end-to-end solution tailored to our material flow, whereas the others were focused on selling their solution and not a holistic approach. I would recommend Kardex to other companies – and have actually – just due to the way that they support in the whole initial design and sizing… but also in actually implementing the system on-site.”

Rhiannon Fisher, MAHLE Aftermarket Head of Business Excellence for the North America region, adds, “The support provided by Kardex exceeded expectations. During the design process they were very hands on. They provided support on-site during the entire process and ultimately delivered a turnkey solution.”

Fred Fox, Director of Project Success for the Kardex Solutions AutoStore team, explains that Kardex offers clients the flexibility to either leverage Kardex FulfillX, the purpose-built software package designed specifically for AutoStore end-user solutions, integrate other warehouse management systems (WMS), or utilize their own software. In the case of MAHLE Aftermarket, it chose to integrate with its existing SAP Warehouse Management System. “Together we got a really good solution in place and that’s just part of who we are and what we want to do,” Fox states.

Following the success of the Olive Branch project, MAHLE Aftermarket automated a second operation in Décines-Charpieu (Lyon), France, including 22,440 storage bins, 7 robots and 2 workstations. MAHLE continues to evaluate its other locations worldwide to assess if AutoStore empowered by Kardex can enhance customer service, increase efficiencies, and standardize its operations.

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SVT and Kardex Partner for Pick and Pack

 

Webinar: Empowering People, Enhancing Performance

Posted on by David Priestman

A new Webinar from Logistics Business is now available to watch on-demand. In association with Koerber Supply Chain and BES, Editor Peter MacLeod talks to Alex Parkinson, Business Analyst at Koerber about a warehouse upgrade project for BES in Birmingham. BES Operations Manager Steve Standley explains the before and after set-up for picking and ecommerce and what benefits automation, WMS and voice tech have brought.

Watch the Webinar here now.

BES are a plumbing, gas and heating trade supplier selling products and brands ranging from Bosch tools to Danfoss thermostats, Grohe taps to Grundfos pumps, Triton showers to Bostik glue. This inventory, in a 80,000 sq. ft. DC in central Birmingham, with 15000 SKUs and 1500 orders per day is a challenge in terms of suitable storage, picking and despatch. The company went from a paper-based operation to an automated voice and WMS solution in a project with Koerber Supply Chain.

The key benefits were:
• 15% reduction in total staff hours used
• 43% increase in productivity
• 88% reduction in training time for new staff
• 50% reduction in staff needed to check orders after picking
• 5 tonnes of paper saved per year (750,000 sheets) + printing costs
• Pick-up times on collection orders reduced to 30 minutes

Flexible Solution Required

“We brought technology to the workplace,” Operations Manager Steve Standley says. BES is a 45-year-old company and ecommerce took-off during covid. “Initially, for the extra orders, we just hired more staff. But that made us top-heavy for pick and pack. We needed to speed up and possibly reduce the head count,” he explains. The old system saw orders generate two copies of every despatch note. One went round the warehouse and one to the customer. There was a lot of walking involved as staff went round the facility to find and collect each item for an order. Having automated these processes considerable efficiencies have been made. BES upped staff pay and amended hours as well.

“It was a bit chicken and egg,” Standley says. “Should we introduce technology first or introduce efficient practises?” A new picking solution was required to help with the additional volumes. Installation, which commenced in March 2023 and was completed last August, needed to be done whilst order numbers continued to grow. “Testing was straightforward. Training is easy. Showing new starters the aisle and stock locations is the main thing.”

Empowering People
Empowering People

Major customers order in big quantities. Plumbers purchase parts for regular jobs. Consumers buy items for home delivery. BES ship via DX for odd sized and large products (overnight via the DX network), DPD for regular parcels and Royal Mail for items under 2kg. The decision was made to divide the DC into four zones, accordingly, from bulk down to small, plus a VIP area. Workers now wheel a roll cage of small or medium totes to the appropriate zone to pick into up to 20 totes at a time, before returning to the loading area.

Order Prioritisation

Another challenge for the upgrade project was to reduce the time taken to pick items meant for collection by customers on-site to be halved, to just 30 minutes. Instead of printed orders being sifted through, the new picking system recognises the warehouse’s own postcode as the destination. “It then jumps to the front of the queue to pick immediately,” Standley informs. “Its hard to get the balance between collection orders and ones for delivery. An unique balance is achieved.”

The new system includes Koerber WMS, voice tech, modules and middleware, plus the four Kardex Megamat carousels (pictured) that were already in use at the DC. The picker no longer needs to input part numbers on the carousel’s control panel. This is a no-touch solution thanks to the Koerber API ordering items in batches. Quite a lot of work was done by Koerber in achieving this interface. “We did have two staff per machine,” Standley continues, “now one person goes to it (and says ‘Ready’) when around 30 orders are ready. So they can go, pick elsewhere and come back. There’s less walking involved.”

What about fast-moving items and stock location? “We wanted accuracy. Quality was paramount.” Standley emphasised. “Phase 2 of the project will take us further, handling inbound products from suppliers and maybe having a dedicated area for fast-movers. We’re also looking at same-day delivery options.”

Watch more webinars here

Kardex Introduces FulfillX at MODEX

Posted on by David Priestman

Kardex, a world leading manufacturer of automated storage and retrieval systems (ASRS), is presenting Kardex FulfillX – an innovative warehouse execution system designed specifically for AutoStore empowered by Kardex systems – at MODEX 2024. Kardex FulfillX takes the unexpected surprises out of go-live and allows new AutoStore systems to ramp-up faster and meet or exceed business cases in as little as 6 months. Showcasing its latest developments in automation software, MODEX visitors will experience a new way to maximize automation and robotics potential in Atlanta, March 11 – 14, in booth B6410.

In addition to new developments in warehouse software, visitors will also be able to experience live demonstrations of Kardex’s Intuitive Pick Assistant that projects relevant picking information directly onto the surface of the access opening for both Kardex Remstar and AutoStore ports. This user-friendly picking display responds to movements and enables ergonomic, fast, and error-free picking.

Through the use of digital tools, visitors will experience Kardex’s entire portfolio of solutions, including vertical lift modules, vertical carousel modules, vertical buffer modules and AutoStore systems, come to life using augmented reality. Comprehensive software packages as well as service and modernization concepts complete the portfolio. Furthermore, Kardex is a global AutoStore partner. The powerful and space-saving solution for fast and efficient processing of small parts orders fits ideally into the existing solution portfolio of Kardex AG.

Cube storage

Commenting on the capabilities of FulFillX, AutoStore Partner Sales Manager, Matt Savoie says, “Kardex’s innovative FulfillX warehouse execution system is a great fit for AutoStore, enabling our market-leading warehouse automation systems to do more and exceeding our customers’ expectations of what is possible with cube storage. Being able to ramp up systems faster without any surprises provides reassurance and the confidence companies need to meet and exceed their business goals.”

President of Kardex Solutions Autostore, Mitch Hayes, adds, “MODEX 2024 is the ideal opportunity to present FulFillX to a wide audience and showcase its possibilities. As a global AutoStore partner, we have developed a warehouse execution system that can provide remarkable results in just 6 months and is the fastest order fulfilment system per square foot on the market. We are looking forward to meeting with visitors to the expo and demonstrating how FulFillX, our Intuitive Pick Assistant, and AutoStore can help to transform their warehouse operations.”

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SVT and Kardex Partner for Pick and Pack

 

Transforming Ecommerce Warehouse

Posted on by David Priestman

Next day delivery is a logistical challenge that warehouses often require an upgrade to achieve. David Priestman visited such a facility in Birmingham.

BES are a plumbing, gas and heating trade supplier selling products and brands ranging from Bosch tools to Danfoss thermostats, Grohe taps to Grundfos pumps, Triton showers to Bostik glue. This inventory, in a 80,000 sq. ft. DC in central Birmingham, with 15000 SKUs and 1500 orders per day is a challenge in terms of suitable storage, picking and despatch. The company went from a paper-based operation to an automated voice and WMS solution in a project with Koerber Supply Chain.

The key benefits were: 15% reduction in total staff hours used; 43% increase in productivity; 88% reduction in training time for new staff; 50% reduction in staff needed to check orders after picking; 5 tonnes of paper saved per year (750,000 sheets) + printing costs; Pick-up times on collection orders reduced to 30 minutes

Flexible Solution Required

“We brought technology to the workplace,” Operations Manager Steve Standley told me. BES is a 45-year-old company and ecommerce took-off during covid. “Initially, for the extra orders, we just hired more staff. But that made us top-heavy for pick and pack. We needed to speed up and possibly reduce the head count,” he explained. The old system saw orders generate two copies of every despatch note. One went round the warehouse and one to the customer. There was a lot of walking involved as staff went round the facility to find and collect each item for an order. Having automated these processes considerable efficiencies have been made. BES upped staff pay and amended hours as well.

“It was a bit chicken and egg,” Standley said. “Should we introduce technology first or introduce efficient practises?” A new picking solution was required to help with the additional volumes. Installation, which commenced in March 2023 and was completed last August, needed to be done whilst order numbers continued to grow. “Testing was straightforward,” Standley recalls. “Training is easy. Showing new starters the aisle and stock locations is the main thing.”

Major customers order in big quantities. Plumbers purchase parts for regular jobs. Consumers buy items for home delivery. BES ship via DX for odd sized and large products (overnight via the DX network), DPD for regular parcels and Royal Mail for items under 2kg. The decision was made to divide the DC into four zones, accordingly, from bulk down to small, plus a VIP area. Workers now wheel a roll cage of small or medium totes to the appropriate zone to pick into up to 20 totes at a time, before returning to the loading area.

Order Prioritisation

Another challenge for the upgrade project was to reduce the time taken to pick items meant for collection by customers on-site to be halved, to just 30 minutes. Instead of printed orders being sifted through, the new picking system recognises the warehouse’s own postcode as the destination. “It then jumps to the front of the queue to pick immediately,” Standley informed. “It’s hard to get the balance between collection orders and ones for delivery. An unique balance is achieved.”

The new system includes Koerber WMS, voice tech, modules and middleware, plus the four Kardex Megamat carousels (pictured) that were already in use at the DC. The picker no longer needs to input part numbers on the carousel’s control panel. This is a no-touch solution thanks to the Koerber API ordering items in batches. Quite a lot of work was done by Koerber in achieving this interface. “We did have two staff per machine,” Standley continued, “now one person goes to it (and says ‘Ready’) when around 30 orders are ready. So they can go, pick elsewhere and come back. There’s less walking involved.”

What about fast-moving items and stock location? “We wanted accuracy. Quality was paramount.” Standley emphasised. “Phase 2 of the project will take us further, handling inbound products from suppliers and maybe having a dedicated area for fast-movers. We’re also looking at same-day delivery options.”

Read more here:

Find your Warehouse Rhythm

 

 

 

Intralogistics Software Partnership

Posted on by Keith McKinley

Kardex has agreed a strategic partnership with Addverb in the area of intralogistics software. Addverb is a robotics and warehouse automation company based in India. The cooperation combines Kardex’s expertise in the area of compact storage systems with Addverb’s outstanding warehouse management technology. Addverb’s highly innovative warehouse management system is based on a modern microservices architecture and fully operable in the cloud.

The partnership between Kardex and Addverb enables an integrated and efficient solution package with the latest technologies in the area of warehouse management and automation. The overall package of Addverb software and Kardex storage systems offers seamlessly integrated and optimized storage processes for companies of all sizes in all industries.

Addverb’s warehouse management solution is based on a microservices architecture that makes it seamlessly scalable and extremely flexible. In addition to which it features a user-friendly interface that eases the implementation and administration. With its algorithms optimizing the handling of resources and materials, the Addverb system ensures optimized workflows and greater productivity. The cloud-based architecture meanwhile guarantees global access and real-time data for optimal decision-making with the highest possible security standards.

The partnership between Kardex and Addverb is an important step forward in the advancement and innovation of warehouse management technologies. Both companies are convinced that their joint effort will contribute to boosting the efficiency and agility of companies worldwide.

“Thanks to the partnership with Addverb, we are able to offer our clients one of the most advanced warehouse management solutions for highly efficient storage. The combination of our technologies will set new standards in the integration of logistics systems” emphasizes Dr. Volker Jungbluth, Head of Corporate Technology at Kardex.

The strategic partnership enables extensive synergies between the two companies. “Together with Kardex, we will be able to offer our clients first-class solutions that will revolutionize their warehousing processes and make them more competitive”, says Pieter Feenstra, CEO Addverb EMEA.

Proactive Monitoring and Maintenance

Posted on by Keith McKinley

In times of increasing competitive pressures there is a need for optimal productivity, it is essential for companies to guarantee the permanent operational readiness of their automated storage and retrieval systems in the warehouse.

“Kardex customers don’t just seek the perfect solution, they crave the assurance that it’s smooth sailing all the way. Because let’s face it, in the fast-paced world of logistics, even if a hiccup occurs, business must go on. True success lies in seamlessly integrating business and process continuity into every solution we offer,” says Michael Tyler, LCS Director at Kardex.

Proactive Monitoring and Maintenance with Remote Support from Kardex is a digital solution that helps companies ensure the optimal productivity and operational readiness of their automated storage and retrieval systems in the warehouse. It includes two main features: Remote Assistance and Remote Analytics.

Remote Assistance allows operators to continuously monitor their Kardex Remstar automated storage and retrieval systems. They can request technical support directly from the storage unit, providing all the relevant information to the support team. The support team can then assist in solving any problems remotely. If the system is down, it automatically reports the issue, ensuring quick reaction times and efficient assistance. Simple user errors can be fixed remotely, and if a part is needed for repair, the remote service technician is aware in advance, eliminating long wait times for spare parts and reducing system downtime.

Remote Analytics provides users with access to all unit data on an online service portal. This allows them to view the data of their networked systems from anywhere via a web browser. They can use the live overview to verify the status of the units at any time. The data includes information on the status of the machines, system performance metrics such as the number of cycles, and any potential error history. By tracking the number of cycles, users can determine when system maintenance should be performed based on actual usage, rather than relying on factory standards or averages.

Monitoring and Maintenance
Monitoring and Maintenance

Kardex ensures the security of sensitive data by implementing measures such as two-factor authentication, secure storage of data, and data transmission channels protected by state-of-the-art firewalls. Remote Support is an important part of Kardex’s service offering to guarantee maximum success in storage logistics operations. It helps customers maximise the efficiency of their units and ensures business continuity by minimising system downtime and optimising maintenance schedules.

See How Kardex Remote Support Works: Video Animation

How AI Can Transform Intralogistics

Posted on by Keith McKinley

There are many safety and efficiency gains to be experienced with the help of artificial intelligence, especially if technology is allowed to coexist with humans – as Kardex states in its new publication.

Despite the complexity, initial operating costs, and resource-intensive implementation, AI has emerged as a crucial Industry 4.0 solution. AI can help companies meet challenges linked to increased customer demands, new and existing needs for streamlined logistics, and labour shortages.

In the publication “Warehouse Insights: 4 Ways AI Transforms Intralogistics”, Kardex, one of the world’s leading manufacturers of vertical storage systems and customised warehouse solutions, takes a deep dive into key elements of AI technology that will no doubt transform intralogistics.

It concludes that AI can help reduce costs while maintaining or even increasing productivity. For example, AI-powered automated storage and retrieval systems, which process and detect patterns in large amounts of data, can determine the optimal placement of items and predict purchase needs. There are also great opportunities for AI in predictive maintenance.

AI and warehouse staff

It is also highlighted that AI and humans can advantageously coexist, not least to ensure optimal security. Robots can perform tasks that are considered dangerous and demanding for humans and AI can monitor storage spaces and equipment to identify potential safety risks. At the same time, warehouse staff are freed up for more dynamic roles.

There is still a lack of knowledge among industrial companies about how they can benefit from AI. This is where Kardex wants to guide.

“We have a deep understanding of the distinct challenges faced by our customers. By closely monitoring inventory challenges and staying up to date with the latest technology trends, we continuously adapt our solution to ensure that our customers’ facilities always stay at the forefront of innovation.” Says Debra Grimwood, Marketing Manager at Kardex UK.

Kardex installs and services both simple, scalable solutions and large, fully automated flows for customers in e-commerce, electronics, production, automotive and the food industry.

Read “Warehouse Insights: 4 Ways AI Transforms Intralogistics” here.

Vertical Lifts, Ahead of the Curve

Posted on by Keith McKinley

Traditionally a step ahead of the game with its vertical lift products, today, Kardex is a leader in warehouse automation. Peter MacLeod asked Kardex New Business Director for UK & Ireland Aaron Thornton to bring us up to date.

Aaron Thornton was persuaded to join Kardex after spending 20 years at a competitor. “When I was previously selling vertical lifts, it used to annoy me when customers would say they needed a ‘Kardex’. I’ve always had respect for the organisation, and a big part of the attraction of joining Kardex [two years ago] was their future commitment to automation. It is an organisation with a very stable background, excellent branding in the market and is correctly perceived to be the market leader. The company has a reputation for quality and stability.”

As Kardex continues its drive into the wider automation field, it has widened its focus from its previously core products – vertical lifts and carousels – and more on its newer technologies such as the Vertical Buffer Module. This, in conjunction with its picking software system (PPS), is driving the company to new heights and new segments.

“We’re a force to be reckoned with,” says Thornton. “We’re now able to attract a customer base that Kardex may not have communicated with previously, for example 3PLs and ecommerce businesses. We’re now looking at integration with conveyors, AMR solutions and robotics. Last year we also took on the AutoStore products to further widen our portfolio.”

My first touchpoint with Kardex would have been at an IMHX trade show in the early noughties. At the time its stand was dominated by a vertical lift that reached high into the rafters. “Back then, we were very product-led,” Thornton explains. “We don’t often take machines
to shows now. Yes, we have a leading product portfolio and that will continue to serve for many decades to come, but if you simply take a carousel or a vertical lift [to a show], that’s what you end up getting enquiries for. Kardex are now so much more than that.”

A solutions provider, Thornton says Kardex’s approach to Industry 4.0 is led by its software. “It takes our product range and lifts it to a different dimension. We also lead with pick technology and have a fantastic service offering called remote support. This enables us to dive
into the machines remotely in order to carry out assessments, for example servicing or cycles. We can see how the machines are performing live and plan preventative maintenance. That offers us a different dimension of sales support, which is a very exciting place to be.”

Kardex is particularly strong in an area Thornton calls ‘first-step automation’. “This is how we work with predominantly SMEs and larger businesses in order to lead them into their first foray into automation. “We are adapting as an organisation. We have robotics, conveyors, AMRs… That’s where the growth of the organisation lies, because that’s what customers demand. Automation was always something to
do with the big boys, but we can offer a level of automation at a relatively low cost, and that’s what makes us different.”

Vertical Lifts

Two major themes are emerging in 2023: labour shortage and high energy costs. Thornton believes Kardex is well equipped to address both of them. On the former, he says: “With a couple of machines and very good software we can manage pick patterns and throughputs that would previously require four or five people. We have discussions every week with our customers about the labour shortage, and we can help them overcome that.”

On the latter, he says: “We are always looking at the technology within our products to increase our green credentials. We have LEDs within
the machines to see what we can do to help lower customers’ energy bills. Companies that use a lot of automation look at their suppliers to
see how they can help them with that – we’re seeing kilowatt usage on motors becoming quite common in tenders.”

With a nod to Kardex’s heritage, this is a different company to the one I first encountered 20 or so years ago, and has its targets firmly set on the automated future of logistics.

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