A high degree of automation without human intervention is particularly suitable for production areas with repetitive tasks where absolute precision is required. © Aimtec

The decisive factor for the introduction was a large-volume order in the field of electromobility with 20 components and a high demand for logistics processing. "We were aware that logistics was the linchpin in successfully completing the order," explains Michael Kuhn, Head of Organization at Scherdel. "The logistical processes had to run smoothly and every part had to be in the right place at the right time." Overall, Scherdel wanted to minimize the transport processes, standardize the stock-keeping processes and bring the material supply as close as possible to the production facilities. Other reasons for automation: a lack of and insufficiently qualified specialists, high demands on technical cleanliness and protecting production from damage.

The project enters the start-up phase

The initial phase of the project began in 2018. As a first step, Scherdel organized a two-day workshop with Servus as the hardware supplier. The participants analyzed the logistics processes: Which products are moved where and how many interactions take place between which positions in production? The workshop revealed that the site needed a WMS.

The Scherdel project team then had to hold internal meetings to convince management to invest in a fully automated intralogistics solution. After the green light was given, the kick-off with Servus and Aimtec as strategic digitalization and integration partners took place in February 2021. Aimtec has been working with companies in the automotive industry for more than 25 years to efficiently drive forward their complex integration and transformation processes in warehousing, logistics and production with knowledge, best practices and digital expertise.

The first implementation steps

In the first step of the dark warehouse introduction, Aimtec implemented its DCIx digitalization platform to connect the ERP system with the processes and technologies in the production facility. The DCIx platform can connect logistics, production, quality, automation technologies, delivery, machines and people and provide an immediate overview of the entire company operation through horizontal and vertical integration.

This was followed by the integration of seven autonomous transport robots (ARC, Autonomous Robotic Carrier) from Servus and an automated small parts warehouse (AKL) consisting of a rack with three automated rows of shelves and three separate elevators for a total of 6,000 storage positions. As of May 2023, Scherdel was using two rows of racks with 4,000 storage locations. The third, with a further 2,000 storage locations, is due to be activated at the end of 2023. The seven ARCs serve two work stations for loading and unloading.

Employees can keep track of which task the technology is processing at all times. © Aimtec

"The particular challenges of the project included the timely introduction of DCIx and the additional programming work due to a new software version of Servus in the middle of the component tests," says Michael Kuhn. "Aimtec mastered these hurdles with ease. In Aimtec, we have an experienced partner with experience and expertise in complex digitalization projects and in-depth knowledge of the automotive industry. Aimtec immediately understood what we needed and what the perfect solution for us should look like."

Went live in no time at all

The project was implemented in a very short time: there were only twelve months between kick-off and commissioning. After the go-live, the new system went into daily operation. At the entry and exit points, users now scan the material stored in standardized KLT boxes. This creates a task management system. If a user enters that a box is to be brought to or collected from the shelf, the system creates an entity to manage the tasks of the technology in question.

The autonomous transport robots, which run on rails, ensure the supply and removal to the AKL. They are battery-operated. A charging station charges them regularly as they pass. Once at the rack, an independent elevator takes the robot to the appropriate floor. It then places the box in the desired shelf position or removes it from it. At all times, the employees keep track of which task the technology is processing, which phase it is in and from where and to where the robot is moving. They also have an overview of all the material and stock levels in the automated warehouse. In future, Scherdel plans to store not only materials, but also finished products and empties there.

An important element of the solution is the monitoring of current workstation capacity and robot utilization. DCIx controls storage taking into account the requirements for retrieval, which optimizes the utilization of the individual transport robots. The system also registers error states. In this case, it marks a task as faulty and the transport robot with the material moves to a special workstation.

Fast ROI, high acceptance

With the new technologies networked into a platform and controlled by DCIx, Scherdel has a flexible warehouse solution that is ideally equipped for future requirements. All processes run autonomously, i.e. without human operation. Scherdel benefits from accelerated logistics processes and fewer personnel required for production loading. The company anticipates an ROI of five to seven years. Process optimization and employee training are a constant focus for the automotive supplier. The better both succeed, the faster the ROI will be achieved.

Scherdel successfully mastered the "change of mindset" - and also thanks to the intensive support from its digitalization partner Aimtec. The company involved employees in all processes right from the start, communicated openly and took plenty of time to answer all questions. From a technological perspective, the course has been set for future growth thanks to Aimtec's flexible platform.