Transparent processes using SAP LES
In September 2009, the newly built logistics centre of Schülke & Mayr GmbH was put into operation in Norderstedt. Together with leogistics GmbH, the group implemented a solution based on the SAP LES WM (Warehouse Management) component of the SAP ERP (Enterprise Resource Planning) that enables 100% radio-controlled storage and retrieval of pallets.
Schülke & Mayr GmbH, a company of the Air Liquide Group, is internationally active in the fields of hygiene and infection prevention, microbiological quality management (MQM) and chemical technical preservation. The product range includes disinfectants, antiseptics, preservatives, biocides, medical skin care products, deodorant active ingredients and system cleaners. In addition to more than 18,500 parking spaces in the four compartments of the new high-bay warehouse, the Hamburg Norderstedt logistics centre houses the complete domestic and export order picking.
Hazardous materials and packaging materials are mainly stored here. The new high-bay warehouse serves both to supply production at the company's own location and to supply customers at home and abroad. Of the approx. 50 employees, around 250,000 pallets are stored and retrieved annually via ten gates.
Set up as a warehouse unit-managed warehouse, it offers not only high-bay warehouse management but also integration into the production supply system. Various barcodes in EAN / UPC format are scanned. Barcode control is carried out via the SAP standard component for coding / decoding and printing barcodes.
All forklifts and stacker cranes (RGB) are equipped with a radio terminal and a scanner. Mobile trolleys with radio terminals, radio scanners and label printers are also available for loading and receiving goods. The RF dialogs on the terminals are mapped via the SAP ITS (Internet Transaction Server) and run in a Windows XP environment with IE8.
Based on the queue control of the SAP WM, a transport chain is formed in a specially developed forklift control system, which can also be processed across forklifts in the respective storage and retrieval scenario (multi-stage storage and retrieval process). At the centre of the transport chain are the rack heads of the high-bay warehouse, via which the storage and retrieval operations are handled and at which the pallets are transferred from one conveyor vehicle to the other (front stacker to RGB / RGB to front stacker).
All forklifts and the four storage and retrieval machines in the high-bay warehouse are automatically controlled via a radio dialogue developed in-house. The stacker resources are controlled via the customer's own control tables, which are used during transport order processing. The respective forklift driver or stacker crane driver scans any pallet in the goods receipt zone or at the rack head. The system determines the next destination and offers this for confirmation at the stacker terminal. Removals from the high-bay warehouse are given to the stacker crane driver, controlled by priority.
As part of the customer-specific radio dialog, an integration into Quality Management (QM) was created, which makes it possible to carry out a trial relationship during goods receipt processing. Furthermore, a cross-docking functionality was implemented in which storage in the high-bay warehouse is omitted and the user is able to route pallets from goods receipt directly into the goods issue zones.
"With innovative ideas and an eye for solutions that are appropriate to our environment, leogistics has helped to ensure that we have implemented modern and efficient logistics with IT support, says Lars Lemke, Head of IT at Schülke & Mayr GmbH. "Thanks to its experience and versatile know-how in the IT and logistics sector, leogistics contributed to the success in all phases of the project".
In addition to the automated control of the forklifts and the customer's own radio dialogue, an innovative storage strategy was implemented which above all covers the complex requirements of hazardous material management within the warehouse. In addition to the instruments available in the standard system, the storage strategy also takes into account the legally permissible quantities of hazardous substances for the property as well as the ban on mixed storage. The core of the putaway strategy is a check of the quantity of hazardous substances across all storage types. Additional influences on the determination of the final storage bin for a material are the respective rack header occupancy at runtime and the general storage bin occupancy in the storage types of the high rack storage area at runtime.
Since the implementation was partly based on existing structures, a custom-fit system was created with a manageable effort.