June, 2018 Continued from previous page


human error and can significantly lessen the amount of safety stock held.


Easy to Install The sensors can be fitted easily to virtually any


flow rack system. The removal of a bin from a rack will automatically signal to logistics the new stock level status, ensuring priority driven replenishment. Manual errors, such as forgotten, misplaced


or damaged kanban cards, can become a thing of the past. There is no need to scan removal of bins from a location, reducing the danger of double bookings or incorrect stock levels. The transmitted data is shown in various dis-


play views in the StockSAVER software. “Installing and setting up the hardware and software was real- ly intuitive and there wasn’t the need for a large project team to oversee the task,” says Alicia Schwald, joint project leader and industrial engineer at Auto-Kabel. The control station view gives a


complete overview of the exact stock levels at the workstation. A require- ments list shows the priority for re- plenishment and creates a to-do list for logistics staff to work with. This helps to avoid errors and optimizes the replenishment process. The software can also provide


analysis of usage so that processes can be improved. The user can also export material movement data. “We have now installed Stock-


SAVER in production control, logis- tics and manufacturing and make the most use of the control station and re- quirements lists,” says Engelhardt. After installing the system,


Auto-Kabel’s workers no longer had to leave their workstations to seek help from logistics. The control sta- tion displayed the stock levels, as well as the part numbers and stock locations, the priority for replenish- ment, and the correct number of bins per part number. “Right after setting up the system we were able to reduce idle time and safety stocks,” explains Schwald. “The project paid for itself within six weeks.”


Place by Light “We had another request after we


completed the first trial,” says Engel- hardt. “In order to achieve an even higher degree of safety and avoid any danger of bin misplacement, we want- ed to introduce a ‘place by light’ system on the flow racks.” This would make it even more obvious to the logistics oper- ator precisely where to replace the re- plenishment bin. “The extension of the system with lights was very important for us and we were very pleased when WERMA was able to meet our request, which they can now offer as standard to all WERMA customers.” With the additional place by light


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Centrally located screens allow logistics staff to see at a glance where material is required.


www.us-tech.com Stock Replenishment with WERMA’s StockSAVER


LEDs, the stock operator sees a green LED at the head of the correct stock location, after scanning the barcode on the bin to be refilled. If the bin is placed in the wrong location, a red LED is lit.


At Auto-Kabel, flow racks with stops are used


so that a bin can be removed and replaced in its orig- inal position, preventing the next bin from sliding down and signaling stock movement in the software. This is an important feature for the process, ensur- ing that replenishment is only activated when the next bin has been pulled through the stop. “All our staff, from the team leaders to opera-


tors, have been won over by the simple functional- ity of the system,” says Englehardt. The extremely short payback period of the equipment is allowing the company to envision future applications for the system as well. “During the workshops we often present ideas from different locations and we will definitely be recommending rolling out Stock- SAVER to our other subsidiaries.” Contact: WERMA USA, Inc., 6731 Collamer


Road, East Syracuse, NY 13057 % 315-414-0200 fax: 315-414-0201 E-mail: us-info@werma.com Web: www.werma.com r


Page 35


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