This page contains a Flash digital edition of a book.
INSIGHT


A benchmark in fastener distribution


These days there are quite a few large-scale, automatic warehousing and logistics facilities across the European fastener industry. Inevitably in a close knit industry each one draws from the experience, sometimes the mistakes, of the others. The Keller & Kalmbach facility at Hilpolstein, though, sets a new bar for future fastener logistic centres and possesses all the qualities to pass the test of time.


D


r Ingomar Schubert is a passionate and highly informed guide to the Keller & Kalmbach logistic centre. He ought to be – recruited direct from university, where he specialised in logistics systems


and technology, the project was quite literally his from conception to delivery. “It is the most ambitious construction project in the company’s history,” says Dr Schubert. It was also one of Jungheinrich’s largest installations. Today, as head of supply chain management its operation remains a core element of his responsibility. The overall site extends across 44,000 square metres; of


which 10,000 square metres is currently occupied by buildings, designed and built to ensure future expansion can be seamlessly integrated. The automatic pallet warehouse is 40 metres high and 120 metres long, providing 35,000 spaces serviced by five picking machines. At a distance from it but in the same plane is an automatic small box warehouse, providing 164,000 carton box spaces plus a dedicated area for storing up to 8,000 empty KLT boxes. Within the warehouses the primary location logic is security – stock of core lines is held in different aisles within the same warehouse and in both warehouses, obviating the risk of delay if there is a mechanical failure. The speed of the warehouse mechanisation makes location by relative speed of demand less significant. Between the two buildings is space to effectively double the pallet warehouse. Similarly there is space to expand the small box warehouse. At right angles and in front of the two warehouses is the building housing the picking zone as well as goods receival,


quality inspection, assembly, packaging and despatch. Ten identical picking stations are each able to handle pallet, carton box and KLTs. Pickers operate from touch screens and each station has a vertical sorter, which sequences the carton boxes extracted from the small box warehouse into the correct order for the picker. Although a greater short term investment it delivers longer term advantages in both efficiency


and speed. Incidentally and perhaps surprisingly, cardboard boxes are preferred – for lower fire risk, lower cost and greater environmental responsibility. Similar boxes are also used for customer deliveries. Speed these days is of the essence, which makes a time


frame of less than one hour to pick an order from the small box warehouse both impressive and invaluable to a business that really values flexibility and responsiveness. Currently the facility handles between seven and eight thousand orders line a day on a two-shift system that employs 30 people. Accuracy is also a prerequisite in meeting the needs of


customers of the calibre Keller & Kalmbach services. Of course, a sophisticated warehouse management integrates a series of checks and balances but there is also clear evidence of simple, straightforward thinking. For example, empty KLTs are stored in the small box warehouse. When the customer order is entered the system selects not just the product but also the empty bin to take it, ensuring a one to one relationship that minimises potential error. Easy in hindsight, but someone has to see the need in the beginning. Something that is true of many facets of this impressive operation.


58 Fastener + Fixing Magazine • Issue 71 September 2011


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76  |  Page 77  |  Page 78  |  Page 79  |  Page 80  |  Page 81  |  Page 82  |  Page 83  |  Page 84  |  Page 85  |  Page 86  |  Page 87  |  Page 88  |  Page 89  |  Page 90  |  Page 91  |  Page 92  |  Page 93  |  Page 94  |  Page 95  |  Page 96  |  Page 97  |  Page 98  |  Page 99  |  Page 100  |  Page 101  |  Page 102  |  Page 103  |  Page 104  |  Page 105  |  Page 106  |  Page 107  |  Page 108  |  Page 109  |  Page 110  |  Page 111  |  Page 112  |  Page 113  |  Page 114  |  Page 115  |  Page 116  |  Page 117  |  Page 118  |  Page 119  |  Page 120  |  Page 121  |  Page 122  |  Page 123  |  Page 124  |  Page 125  |  Page 126  |  Page 127  |  Page 128  |  Page 129  |  Page 130  |  Page 131  |  Page 132  |  Page 133  |  Page 134  |  Page 135  |  Page 136  |  Page 137  |  Page 138  |  Page 139  |  Page 140  |  Page 141  |  Page 142  |  Page 143  |  Page 144  |  Page 145  |  Page 146  |  Page 147  |  Page 148  |  Page 149  |  Page 150  |  Page 151  |  Page 152  |  Page 153  |  Page 154  |  Page 155  |  Page 156  |  Page 157  |  Page 158  |  Page 159  |  Page 160  |  Page 161  |  Page 162  |  Page 163  |  Page 164  |  Page 165  |  Page 166  |  Page 167  |  Page 168  |  Page 169  |  Page 170  |  Page 171  |  Page 172