Wheels are rolling thanks to the overall software concept

Online retail has expanded its position. According to current figures from the German E-Commerce and Mail Order Association, it contributes around 100 billion euros per year to Germany's gross domestic product. Canyon, a manufacturer of mountain bikes and racing bikes, also relies on online retail. Scalable, transparent and customized solutions that support the production and logistics processes are essential. This is the only way to respond to order peaks, which currently lead to waiting times of up to 500 days for bike components.

A new location became necessary

In view of constantly growing demand, fully utilized capacities and different warehouse locations, Canyon wanted to optimize its logistics situation with a new location. The merger of production and intralogistics was intended to make assembly processes more efficient and inventory management, including the associated logistics, more transparent. TUP took on and supported the individual project from conception to implementation.

In a follow-up project with a tight deadline of just three months, TUP extended the software already developed in the first project to another warehouse. TUP tested and implemented the software within a very short space of time, as the modules are version-compliant and compatible, thus enabling the problem-free cross-system networking of additional warehouses.

A warehouse with smart assembly

At Canyon's new production and warehouse near Koblenz, the production chains and material flows were redesigned to cope with the increasing number of orders. "TUP was the right partner to optimize and automate our logistics processes. It was also important to us to have a partner who could provide us with comprehensive support in logistics planning, the warehouse management system and warehouse technology as a general planner - all from a single source," says Canyon project manager André Koch. The requirements for TUP included the digitalization of documentation from incoming to outgoing goods and easier access to all data via mobile devices. In addition, digital, two-stage picking was to be introduced and dynamically controlled line production was to be implemented in assembly.

Customized software package for special challenges

During the construction of the new Canyon factory, TUP was able to implement individual adaptations directly. It was a challenge to connect the warehouse management system (WMS) to the assembly line within a short period of time and to complete the entire process - from the requirements specification to the specifications to commissioning. TUP was able to realize this within the time and budget plan and thus meet the set targets. TUP also developed modular software for Canyon - Smart Mobile Logistics, called TUP.SML. It enables the use of Android-based end devices and commercially available smartphones for mobile data collection in the warehouse as well as the connection of headsets and ring scanners. In the event of a device failure, work can be continued directly by changing devices thanks to the TUP software.

All data and work steps in the entire process chain are recorded and transferred to the TUP.WMS WMS. Transfer to downstream systems such as ERP or MES is also possible. The adaptable TUP.WMS enables dynamic, just-in-sequence assembly services based on the order situation.