The challenge: Increasing global competition and the analysis of internal processes showed that there was a need for action in the area of logistics and supply chain at Magna. A solution was sought that would allow greater flexibility and also increase the depth of added value at the site. To implement these requirements, Magna opted for a solution from Knapp.

The solution had to meet a number of requirements. It had to enable personnel-free internal transportation as required and be implemented by using several existing buildings without any structural measures. In addition, a sequenced supply of the assembly workstations was required, as well as the supply of the production lines with empties and removal of the manufactured parts. Rapid availability of parts to implement the JiT/JiS strategy was also part of the requirements. An interface to Magna's ERP system was also important. Sufficient storage density and expandability of the system for future growth were also essential criteria.

Six open shuttles, 20,300 possible parking spaces

The new small parts warehouse with two aisles for triple-deep storage has space for up to 20,300 storage locations. Six Open Shuttles are directly connected to the small parts warehouse, supply the decentralized production workstations with empty containers and deliver finished parts back to the Evo Shuttle. The Streamline conveyor technology connects the incoming goods area, the shuttle warehouse and the assembly area with the Pick-it-Easy workstations. It is also used for transfer to the Open Shuttles. The Knapp software solution KiSoft One with a web service interface to the Magna host system ensures that everything runs smoothly in the background. All system areas are clearly visualized with KiSoft Scada.

Before being stored in the Evo Shuttle, the order-related painted exterior mirror parts are delivered to the multifunctional Pick-it-Easy workstation. In the decanting process, the mirror exterior parts are checked by the employees, identified using barcodes and married to an empty tray. Empty trays are automatically fed to the workstation. The EasyUse user interface and the ergonomic and intuitive workstation make work easier. The trays then move into the Evo Shuttle via the conveyor system.

Supply of production workstations via AMR

The production lines for the exterior mirrors are located in the adjoining hall. If empty containers are required here or finished parts need to be collected, a transport order is generated in the system. These transport orders are handled by six autonomous mobile robots. The Open Shuttles can transport two containers at the same time and connect the Evo Shuttle with the decentralized production lines. In doing so, they navigate autonomously and safely through the environment and transfer containers to conveyor technology stitches.

If empty containers are required on the line, the containers are removed from the Evo Shuttle once the order has started. An Open Shuttle travels to the conveyor system infeed of the automated small parts warehouse, picks up the containers and takes them to the production line. There, the Open Shuttle transfers them to the transfer stations. Orders that have already been produced are also ready for collection at this transfer station. The Open Shuttle picks them up and takes them to the Evo Shuttle and transfers them to a conveyor system for storage.