Safe handling of various plastic containers and special load carriers with short throughput times, in three-shift operation on five working days a week, resource-saving, ergonomic and standardized: This is what the miniload solution from Stoecklin can do at the Mercedes Benz AG Sprinter plant in Düsseldorf.
Construction of an automated small parts warehouse (AKL) for assembly supply
3-aisle rack construction for 16,000 container storage locations with BOXer storage and retrieval machines and connection to extensive peripherals (conveyor loops to connect incoming goods via processing stations to outgoing goods)
Conveying of up to 360 small load carriers per hour, also for partial removal at the picking workstations and with cross-docking function for multiple or urgently required materials
Up to quadruple-deep storage thanks to group formation and carton grippers designed to carry up to four load units, sequenced storage/retrieval of components in accordance with the specified shoring sequence
The Mercedes plant in Düsseldorf is subject to constantly growing process requirements. In order to map these economically and future-proof them, the decision was made at the beginning of 2017 to invest in an automated assembly supply system - which would streamline processes, shorten walking distances and integrate manual workstations as compactly and ergonomically as possible.
With Stoecklin, Daimler relies on an experienced partner who designs the right solution for every individual situation with standard modules: The new automated small parts warehouse was installed on the 1st floor of an existing building - at 63.5 x 33 m and 6.5 m high.
The 3-aisle rack construction of the small parts warehouse has over 16,000 storage locations with a basic container size of 400 x 600 mm. These are served by three fully automatic BOXer storage and retrieval machines from Stoecklin, which are equipped with a carton gripper.
Primarily plastic containers (VDA-KLTs), cartons and also special load carriers with a permissible total weight of up to 25 kg each are transported, stored and sequenced to the workstations in the correct order - precisely positioned, barcode scannable, turned towards the user, in the correct sequence for assembly - and therefore with a throughput of only 360 small load carriers per hour (up to 600 would be technically possible).
Connected to the new warehouse are extensive conveyor lines including loops, which provide access to incoming goods, specific processing stations and outgoing goods. Manual rack loading, partial removal at the picking workstations and cross-docking of urgent materials in the outbound process - without (re-)storage - are also possible.
An integrated energy management system feeds excess braking energy back into the main power grid. During periods of low throughput, the BOXer can be operated with reduced driving dynamics or put into sleep mode.
