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Dematic Automates Small Parts Warehouse at Siemens Plant

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Featuring an AutoStore™ Empowered by Dematic System for Increased Capacity, High Storage Density and Reduced Error Rates

Dematic announced today that it has automated a small parts warehouse for the Siemens System Engineering Plant (WKC) in Chemnitz, Germany. The factory produces control gears and customized electronic components for the global market. The factory plans more than 1,270,000 material items for the production of its applications in one year.

The compact piece picking solution from Dematic improves the use of warehouse space while automating picking and material flow for production. It features an AutoStore system with more than 45,000 bins for storing parts. In addition to time and cost savings, the Dematic solution provide Siemens with increased capacity, higher storage density and a reduced error rate for assembling components.

“Previously, our warehouse operated with a manual modular racking storage system. This now automates the entire material flow to always ensure a very good production supply that flexibly fits into the work processes at Siemens,” said Carsten Sambo, Head of Inbound-Logistics, Siemens WKC.

Dematic was introduced to Siemens by fellow KION Group member, STILL (a long-standing consulting partner of Siemens). For the warehouse, STILL supplied a racking system for approximately 12,000 slots as well as 2,100 square meters of platform space as part of the overall logistics concept. Dematic worked with Siemens WKC to develop the piece picking solution.

“Siemens has trusted the KION Group for years due to its commitment to excellence in all projects,” said Rainer Buchmann, SVP and Managing Director, Dematic Central Europe. “This project showed the great collaboration between Siemens, Dematic and STILL, and the results prove that working together enable extraordinary results ― more processed orders, less time and fewer errors. A true win for all.”

The AutoStore system has more than 45,000 containers with different compartments so that several unique types parts can be stored per container. Orders are collected by 34 mobile robots that ride on top of the system and reach down into the structure to access containers with requested parts. The robots then transport the containers to one of the five picking stations where the parts are bundled for further processing in production. (Staff previously had to travel long distances to pick individual items.) Conveyor brings the parts bundles to the production area.

To supply the AutoStore system with parts, parcels are unloaded directly from the delivery trucks onto connected conveyor belts and transported via lifts to the workstations in the goods receiving area where they are filled into AutoStore containers. More conveyor belts then carry the containers to transfer cells where they are loaded into the AutoStore system. The connected conveyor technology automates the complete material flow of goods.

Siemens integrated the new warehouse system into its IT structure using ASIS (AutoStore Integration Service), an in-house software solution developed and supported by Siemens Bad Neustadt. It complements SAP and controls the processes between AutoStore, conveyor technology and employees.

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Researchers to Develop Solid Lubricant Coatings for Conveyor Systems

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A research and development team led by Min Zou, professor of mechanical engineering and an Arkansas Research Alliance Fellow, has received a $550,000 grant from the National Science Foundation to develop low-friction, durable, graphite-lubricant coatings for industrial conveyor systems.

Belt conveyors comprise about a quarter of the $7.65 billion global conveyor market, which has expanded significantly in recent years because of e-commerce. However, an enormous amount of energy is wasted in these systems. High sliding friction between conveyor belts and slider bed materials is responsible for more than half of the total energy losses in a flat conveyor system.

The researchers will develop novel graphite coatings that will significantly reduce energy consumption and equipment failure in conveyor systems. The research will also deepen a fundamental understanding of the novel coating technology to enable applications in other fields, which could lead to significant savings in many U.S. industries.

The technology is based on a unique, patented bonding approach, developed by Zou’s group, in which graphite coatings adhere tightly to a substrate material.

After developing and optimizing fast-coating deposition processes for conveyor materials, the researchers will build scalable coating processes for full-sized belt conveyors. They will then build a prototype for evaluating the coating performance and demonstrate the feasibility of the coatings for industrial applications.

The new project is a collaboration between university researchers and industry leaders. Zou’s team at the U of A will partner with researchers at Arkansas State University and Hytrol Conveyor Company Inc., the largest conveyor manufacturer in the U.S.

The researchers use a special machine to apply novel graphite coatings that will reduce energy consumption and equipment failure in conveyor systems.

Robert Fleming, assistant professor at Arkansas State; Ty Keller, Hytrol’s manager of product innovation; and Boyce Bonham, Hytrol’s chief engineer, will serve as co-principal investigators.

The project will support a doctoral student at the U of A, who will serve as the entrepreneurial lead, a master’s student at Arkansas State, and undergraduate students from underrepresented groups. They have benefited from site and national NSF I-Corps training and Office of Entrepreneurship and Innovation support and training, as well as mentoring by Cynthia Sides, assistant vice chancellor for research and innovation at the U of A, and Douglas Hutchings, director of the Arkansas Research Alliance Academy.

Zou’s research focuses on nanoscale materials and manufacturing. She is an international expert on surface engineering and tribology — the study of friction, wear and lubrication in the design of bearings and interacting surfaces in motion. Zou has designed, refined and tested solid lubricant coatings for various applications. The coatings are thinner, more durable and environmentally superior to petroleum-based oil lubricants.

Zou holds the Twenty-First Century Chair of Materials, Manufacturing and Integrated Systems.

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Dematic automates warehouse of kitchen manufacturer Schmidt Groupe

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Dematic has automated the picking warehouse of French kitchen manufacturer Schmidt Groupe S.A.S. at its site in Lièpvre in Alsace. The automation technology provider developed a space-saving solution, featuring a multishuttle system for multiple-deep storage in nearly 6,000 locations as well as special tote conveyor technology. Within the multishuttle system, 12 shuttles control order sequencing. The conveyor system z requested items to various workstations. In this way, the Dematic solution provides complete automation of the previously manual storage and retrieval operation as well as picking goods for the entire material flow.

“The Dematic Multishuttle significantly increases speed, storage density, accuracy, and availability within the picking warehouse,” says Boris Herrmann, Process Manager at Schmidt Groupe S.A.S. “In addition, the overall system enables high throughput rates as well as error-free picking, guaranteeing us efficient and reliable order processing.” As one of the international market leaders for furniture manufacturing and distribution, Schmidt Groupe faced several intralogistics challenges. For example, managing the side panels, doors, fittings, and handles of a customized kitchen required more effective processes, so the company decided to automate the material flow at its Alsace site.

Order picking starts at the small parts workstations. There, operators put required parts into cartons using a pick-by-light system. Cartons are then transported to the subsequent stations by conveyor using special roller and belt conveyor technology that support the logistical processes. If larger items are needed for an order, the small parts carton is loaded onto a tray and stored or buffered in the Dematic Multishuttle, which provides space for 5,760 storage locations on 12 levels. Within the multishuttle system, a dozen shuttles handle automatic order sequencing as well as storage, transfer, and retrieval. The conveyor system then transports the filled totes and trays to the other workstations. A continuous scale checks the weight. When an order is complete, the sequenced totes are checked, cartons are closed, and shipping labels applied.

Dematic has also installed a WMS (Warehouse Management System) that optimally manages stocks and orders according to priority, with the most frequently requested items stored in the most accessible locations. A WinCC process visualization system developed by Siemens was also integrated into the solution for monitoring the technical processes. It enables a simple and clear information flow of all accruing data and provides a user interface. As Thomas Meyer-Jander, Director EMEA and Head of Marketing & Communications at Dematic, explains: “In this way, users have access to the current operation status and can use that data to derive optimizations for improved performance.” The Schmidt Groupe’s assessment is correspondingly positive. Herrmann sums it up, “Our throughput and delivery accuracy goals have been more than met. With Dematic, we have the right supplier – due to their intralogistics know-how and expertise, they have been valuable resource, and our relationship has been characterized by cooperation and partnership.”

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Orion’s Compact RTC Rotary Tower Automatic Wrapper Integrates with Existing Conveyance

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Orion Packaging Systems, a division of ProMach, responded to industry demands by creating a space-saving rotary automatic wrapper that easily integrates with new or existing conveyance.

Orion’s Rotary Tower Automatic (RTC) Stretch Wrapper with Conveyance is the ideal solution for easy integration with 18″ pass-height conveyors due to its compact size, affordability, and the option to expand with additional conveyance.

The RTC is fully automatic and attaches the stretch film at the cycle start, cutting it at the end. The forklift operator simply places the pallet-load on the infeed conveyor and pulls a lanyard switch while moving away to collect the next load. This design increases employee safety by removing them from proximity of the moving rotary arm.

In addition to the compact size, expandability and increased employee safety, the RTC has:

  • 20″ Insta-Thread™ Film Carriage standard with 260% pre-stretch
  • Revo-Logic technology with photo-eye sensor carriage ensuring precise application of programmed wraps and maximizing load containment and film yield
  • Separate up and down film carriage speed control and top and bottom adjustable wrap counts, customizing wrapping for each load
  • Long lasting AC motors and Variable Frequency Drive (VFD) controllers, providing low maintenance
  • Labor saving film tail clamp with cut & wipe that automatically secures film, allowing faster output by reducing per-load wrapping

Orion’s RTC Stretch Wrapper delivers performance and cost-savings to new or existing wrapping systems, providing increased production and output.

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