Kardex Mlog Expands Würth’s High-Bay Warehouse

On behalf of Adolf Würth GmbH & Co. KG, Kardex Mlog expanded the existing 3-aisle fully automated high-bay warehouse at the Northern Distribution Center in Künzelsau-Gaisbach by 4 additional aisles within just 5 months. The project, carried out during ongoing operations with an investment volume of 7.1 million euros, resulted in approximately 12,000 additional pallet spaces.

(Neuenstadt/Künzelsau) Every customer their Würth: Under this guiding principle, Adolf Würth GmbH & Co. KG offers tailored sales and logistics solutions, allowing small craft businesses to focus on their core work just as much as globally operating industrial companies. To achieve this goal, Würth relies on a modular logistics solution for multi-channel distribution, which was awarded the German Logistics Prize in 2009.

Long-term Strategy

The focal point is the company’s headquarters in Künzelsau-Gaisbach, which has had to be expanded several times due to a successful growth strategy. In 2018, the 3-aisle automatic high-bay warehouse (HRL) at the Northern Distribution Center reached its capacity limits. The rapidly growing product range had led to a high utilization of the existing facility, which was to be more than doubled by approximately 12,000 additional pallet spaces. The necessary building was constructed by Würth directly next to the existing high-bay warehouse. The expansion was the result of a long-term strategic orientation of Adolf Würth KG. The areas had already been planned during the construction of the Northern Distribution Center in 1995.

For the technical infrastructure of the approximately 1,360 sqm area, an experienced supplier was sought who could ensure the expansion of the warehouse during ongoing operations. The tender was won by Kardex Mlog, which had already built the existing HRL and has been one of Würth’s suppliers for over 30 years. In addition to a good price-performance ratio, the high investment security and the nearby production site of Kardex Mlog, only 40 kilometers away in Neuenstadt, were decisive factors.

Integrated on 3 Levels

Kardex Mlog built, delivered, and installed 4 storage and retrieval machines (SRM) of type MSingle B 1200 with aisle equipment and automatic control, which were integrated into the existing facility on 3 levels. The single-column SRMs were brought into the warehouse through a roof opening on October 23, 2018. The machines have an operator’s platform, are 35.5 m high, and designed for a load capacity of up to 2.4 tons. With a travel speed of up to 180 m/min and a lifting speed of up to 70 m/min, they can move quickly within the 70 m long aisles.

The SRMs are controlled via the MLOG Control Center – short MCC – programmed by Kardex Mlog. At Würth, it is connected to the existing warehouse management system SAP EWM. Through the system visualization (MVisu) as an integral module of the MCC, all automatic conveyor systems and storage and retrieval machines, as well as their operating states, can be graphically displayed. The visualization allows for interactive handling of the material flow system – from context-related location data processing to information in the event of a system malfunction. Through a standardized interface, the visualization system is connected to the automation devices of the controls, enabling continuous data exchange between the systems.

Smooth Operation

The system visualization was integrated into the existing facility as part of the new construction without disturbing ongoing operations. The same applied to the mechanical and electrical connection of the two systems. The scope of delivery also included the entire conveyor technology, consisting of continuous conveyors, vertical and corner transfer units, and turntables. Additionally, Kardex Mlog was responsible for procuring strapping machines and several fire and machine protection gates. Finally, as part of the project, the safety technology of the old facility was also updated to the latest standards.To ensure smooth operations and close coordination with Würth, the project team from Kardex Mlog was permanently on-site throughout the entire project duration. This commitment paid off: After almost exactly 5 months, Kardex Mlog was able to hand over the new high-bay warehouse to Würth on November 12, 2018, on time. Since then, the logistics of the giant for assembly and fastening materials has become significantly faster and more efficient. “With this expansion, we further improve our service for our customers, as more products can now be accessed during order picking that were previously not accommodated in Gaisbach,” explains project manager Roland Schneider, who is responsible for operational technology at the site. Furthermore, this expansion covers the growth of the coming years and creates the necessary reserve capacity.

Now, the site in Gaisbach has a total storage capacity of 38,990 pallets in fully automated storage areas and another 63,010 pallets in manual areas. If these 102,000 pallets were lined up one after the other, it would correspond to a distance of 122 kilometers – the distance between Dresden and Leipzig.

Photo: © Kardex Mlog