In addition to implementing a state-of-the-art, flexible and scalable intralogistics solution at KW, the aim was to perfectly coordinate the entire warehouse management system with its various warehouses, orders and order picking in order to achieve an optimal, cost-efficient and transparent process. Thanks to the digital twin, the potential offered by advancing digitalization is being fully exploited. "KW stands for quality and innovation. As a racing company, we always set ourselves ambitious goals, and this project is no exception," explains Klaus Wohlfarth, Managing Director and shareholder of KW Automotive. "In the end, Gebhardt was the only supplier willing to tackle our challenging and ambitious goals."

The storage solution in detail

In the first step, Gebhardt implemented the intralogistics. This included the entire logistics process chain and warehousing, divided into the so-called automatic small parts warehouse (AKL) for production supply, the so-called automatic pallet high-bay warehouse (APL), the storebiter multi-level shuttle warehouse (MLS) as an order buffer and an AKL for shipping, including connecting conveyor technology and corresponding workstations. The miniload warehouse for production supply is designed as a shuttle warehouse and has a total capacity of 19,760 storage containers. It is primarily used to supply the assembly department. It consists of three aisles with 23 storage levels each, with 16 levels for storage containers with a height of 170 mm, six levels for containers with a height of 270 mm and one level for containers with a height of 200 mm. Five Gebhardt-Storebiter-One-Level-Shuttle (OLS) are used per aisle.

The APL serves as a warehouse for raw springs for painting and as a replenishment warehouse for the AKL. It consists of an aisle and a Gebhardt Cheetah Heavy storage and retrieval machine. Each side of the aisle has 35 rack columns, five rack levels are provided for low pallets and two for high pallets. The racking can be stored nine deep. The total number of storage locations is approximately 4,266.

The implemented storebiter multi-level shuttle warehouse serves as interim storage for production containers. The containers are stored in the buffer warehouse until the complete production order has been completed and can be made available for the packaging process. The MLS warehouse has 589 storage locations and consists of an aisle and a storebiter multi-level shuttle. In the dispatch warehouse with 13,848 storage locations, the cartons that have been prepared for dispatch in the packing area are temporarily stored. The dispatch warehouse consists of three aisles and one type 716 storage and retrieval machine each. High and low cartons can be stored single or double-deep.

KW Automotive relies on Gebhardt StoreWare to implement reliable, transparent and coordinated warehouse management. This software solution integrates the material flow (MF), warehouse management (WMS) and visualization system in one platform and, thanks to its combinability with the Gebhardt Galileo IoT platform and Galileo Insight, offers the first step towards Intralogistics 4.0.

Digital twin - the key to optimization

The idea of a digital twin as a completely digital image of a machine or system is no longer entirely new. This approach has already proven itself many times over, particularly in commissioning or in the area of services and training. In both cases, it leads to significant cost savings. The reasons: Firstly, errors are detected and rectified during planning and development and the project is implemented and commissioned much more smoothly as it progresses. Secondly, systems or machines no longer have to be taken out of operation for services or training. While companies are already taking advantage of these benefits in many cases, the potential of the digital twin as a basis for continuous optimization is still rarely fully exploited. Not so at KW: By using the digital twin, KW is taking this one step further and also advancing the digitalization of its processes. The company is thus taking advantage of further opportunities, such as the networking of components for intelligent communication, cross-system control and regulation, increased efficiency and high analysis potential.

Whether pallet warehouse, dispatch warehouse including stacker crane or OLS warehouse, Gebhardt created a digital twin of the individual components and system, whereby the simulation of the twin behaves exactly like the real system. All statuses are recorded digitally and combined with all relevant information from the surrounding system to create a continuous and consistent status image. Thanks to this image and the collected data, KW is able to implement a continuous optimization process for its systems and production. Whether emulations of function and performance, real-time monitoring of machines and warehouse technology or status information on individual warehouse components - KW has a full overview of all data at all times and can react accordingly at an early stage. The system runs more smoothly, more efficiently and more reliably. "The cooperation with Gebhardt was very good. They responded professionally and quickly to every request. Thanks to the solution, our processes are much more reliable and faster and we can already see a very good return on investment. At the same time, we are taking full advantage of the benefits that digitalization and the IoT offer us," says Klaus Wohlfarth, drawing a positive conclusion.