Construction work on the new logistics center is in full swing in the industrial area of Röthlein near Schweinfurt in Lower Franconia. A hub for the Europe-wide shipment of Winora and Haibike bikes and e-bikes is to be built here. The cooperation between the Sennfeld-based bicycle manufacturer, which is now part of the Dutch Accell Group, and the logistics company Schäflein, which has its headquarters in Röthlein, has existed since the 1950s. What began back then with the shipment of individual bicycles is now a highly complex bike logistics operation that is currently facing new and exciting challenges.

Rising e-bike sales, more space required
According to research by the Statista Institute, sales of e-bikes in Germany rose from 150,000 units in 2009 to 980,000 in 2018, a trend that Winora is also clearly noticing. While the proportion of non-e-bikes and e-bikes at the Lower Franconian bicycle manufacturer was 80 percent and 20 percent respectively in 2012, the ratio was reversed for the first time in 2017. From a logistics perspective, this development means an explosion in the volume to be stored, as the high-quality e-bikes are packed exclusively in protective cardboard boxes. In addition to the existing central dispatch warehouse for Winora in Röthlein, various other external warehouses were needed to cope with the volume. These will be brought together in the new 25,000 square meter European distribution center. The logistics company Schäflein is investing 18 million euros in this project. "We believe in our customer and its portfolio. With its modern and innovative products from the Winora and Haibaike brands, the Winora Group always has its finger on the pulse of the times," says Managing Director Achim Schäflein.

Increase to 72,000 bikes
With 11,000 square meters of storage space, Winora will occupy more than 40 percent of the new multi-user location. A further 4,500 square meters can be variably booked. In figures, this means an increase in maximum storage capacity from 45,000 to 72,000 bikes in the new warehouse, which will be fully equipped to meet the requirements of bike logistics. "Schäflein AG has been supporting us in our growth for decades and is creating the necessary conditions with future-proof logistics so that we can continue to be successful in a rapidly changing competitive environment," explains Dominik Thiele, Regional Director D-A-CH.

Short distances, 20 loading bays, 2,500 bikes a day
To ensure short delivery times, Schäflein relies on optimized warehouse logistics with short distances and low replenishment costs: frequently requested items - the so-called fast-moving items - are stored in a separate area, while B and C items are stored in high-bay warehouses with a picking area at floor level. Induction-guided stackers are used to remove the wheels, keeping the optimum distance from the racking so that the picker can concentrate fully on the picking process. A total of 2,500 bicycles can then be delivered or dispatched daily via 20 loading gates.

Warehouse logistics 4.0 is under construction here
The logistics experts respond to seasonal peaks in the bicycle trade and growth-related changes in volume at Winora with flexible processes and adapted technology. Depending on requirements, the order picker puts together individual orders completely according to the man-to-goods principle or processes several customer orders at the same time by picking items for several customer orders per compartment with his forklift. In this system, orders are not actually put together until they are dispatched. Additional trolleys on the forklift trucks ensure maximum efficiency. In addition, various automation solutions - such as the use of autonomous forklift trucks and driverless transport systems - are already planned during the construction of the hall to supplement the manual processes.

Transparent processes and shipment tracking
From the delivery of the bikes to the warehouse, through dispatch including individual transport stations, to delivery to the customer - all movements are recorded and come together on a central platform, the Schäflein data cube. If a delivery does not reach certain intermediate checkpoints on time, the logistics experts recognize the deviations immediately and can take corrective action if necessary. The connected retailer is also informed. The order status of the shipment can be viewed at any time via a mobile web application. The application also offers additional services, such as a clear order history and user-friendly complaints processing.