Automation at a high level

Novaltia operates four distribution centers and supplies around 1,000 pharmacies up to five times a day. Constant monitoring of the medicines by a pharmaceutical specialist on their way between the laboratory and the pharmacy guarantees that customers receive original goods in perfect condition. With an order throughput time of between 30 and 180 minutes and operating costs of less than three percent of turnover per year, Novaltia was awarded the Pilot Award for Logistics Excellence.

Software solution

The brain of the highly integrated logistics solution is the KiSoft software package. KiSoft takes care of warehouse and inventory management, warehouse control and the connection of all subsystems in the warehouse. In addition, KiSoft ensures the paperless, guided handling of all logistics processes from goods receipt to goods issue. With the help of the KiSoft i-Point visualization software package, Novaltia is able to centrally switch on and off, monitor and operate both the entire warehouse and individual areas. The warehouse is displayed in one or more images in which the warehouse components are visualized. The system can also be operated remotely via the Internet.

A large part of the product range is stored in the OSR Shuttle system and the storage and retrieval machine (SRM). The OSR Shuttle supplies the goods-to-person work stations and the Pick-it-Easy Robot picking robot. The SRM supplies the Central Belt System with the various picking machines and the manual picking area with replenishment in a time-optimized manner. The new Knapp Store is used to store a wide range of items on an individual item basis. Returns can also be managed with the Knapp Store: The Open Shuttle links the Knapp Store with the returns area.

"The combination of this KNAPP technology enables Novaltia to be one of the most efficient companies in its industry."

Fernando Castillo CEO Novaltia

Order picking

In addition to ergonomics and user guidance, the focus in the picking areas is primarily on the time-optimized supply of goods.

• Central Belt System: Three picking machines connected in series with different types of ejectors are integrated here. These cover the different requirements for goods rotation.
• Manual picking: At four work stations, oversized and fragile items are picked manually and paperless with RF terminals from the flow racks of the SRM or from static racks. The RF technology guides the employee.
• Pick-it-Easy: Medium and slow-moving items are stored in the OSR Shuttle and are prepared for picking at the Pick-it-Easy work station according to the goods-to-person principle. The Pick-it-Easy Robot picking robot is also available for picking from the OSR Shuttle.
• Pick-to-belt for original cartons: Large order quantities are picked using the pick-to-belt method. The original cartons are picked from the excess stock using RF terminals, transferred to a conveyor line and transported directly to the dispatch area.
• Chilled items (2 °C - 8 °C): Refrigerated items are picked into a separate refrigerated container using RF terminals. For transportation to the dispatch area, several refrigerated containers assigned to the same delivery route are combined in a separate box and assigned to the corresponding dispatch ramp. Temperature probes are placed in the boxes.
• Rush orders: These are marked by the ERP system in a special tour. KiSoft ensures that these orders are started promptly and picked quickly.

Transportation systems

The storage areas are connected via conveyor technology, which transports the storage and order containers quickly to their destination stations. The conveyor technology is now supported by the Open Shuttle free-moving transport system. It moves flexibly in the open space and can therefore fulfill complex transport tasks. At Novaltia, for example, it transports returns to the Knapp store. The returns are recorded and transferred to the Knapp store - which automatically stores the items. They are then available for picking again.

Outgoing goods

After the final inspection, the fully automatic addition of the delivery bill, capping and lacing, the plastic containers are distributed to the 720 ramps according to the assigned routes.

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