Long-term partnership

Danish furniture retailer JYSK Nordic A/S has almost doubled the storage capacity of its distribution warehouse in Nässjö, southern Sweden, by setting up a third high-bay warehouse (HBW). "We were dependent on the operation of nine external warehouses with corresponding 'goods tourism'," says Annika Löfgren, Logistics Manager at JYSK. "With the capacity expansion, we wanted to consolidate the storage of goods at one location and optimize the processes."

Together with JYSK and an external planning company, SSI Schaefer developed the logistics concept for the new HBW and the modified material flows and generated an optimal solution in project simulations. With more than 165,000 pallet spaces, fully automated processes and high-performance logistics software, JYSK in Nässjö has had one of the largest and most modern distribution warehouses in Scandinavia since the beginning of 2016. "With daily capacities of up to 1,100 pallets for incoming goods and 1,000 pallets for outgoing goods, as well as the daily processing of around 6,000 pallets for order picking or entire pallets on the conveyor system, we have already increased our throughput considerably. The consistent separation of material flows and the significantly increased efficiency of the picking processes offer us good potential for further growth," notes Löfgren.

Following successful large-scale projects in Denmark and Poland, furniture retailer JYSK and SSI Schaefer are continuing their collaboration: the distribution warehouse in Nässjö in southern Sweden has been expanded by 76,000 additional storage locations with the installation of a third high-bay warehouse.

JYSK placed the order at the end of 2013. One and a half years later, in July 2015, the furniture retailer was able to start closing the external warehouses and storing the goods in the 76,000 storage spaces of the new, 10-aisle HBW. Since January 2016, all distribution for the JYSK stores in Sweden and Finland has been handled exclusively via the warehouse location. The new HBW acts as a replenishment warehouse for the two existing HBWs. Retrievals can be made directly to the picking stations via a conveyor bypass.

Multiple, parallel project steps

The project was realized in several stages. While operations continued in the existing facility and work began on the new HBW, the warehouse built directly in front of the planned new building in an earlier construction phase was converted into a pure incoming goods hall with new conveyor technology and a flat storage area for special pallets. "A platform level was installed in this wing of the logistics center, on which part of the conveyor technology is installed to keep space free for forklift traffic on the floor level," explains Anders Bohlin, Sales Manager at SSI Schaefer.

At the same time, SSI Schaefer used project simulations to develop an optimal material flow concept with separate incoming and outgoing goods flows. "On the one hand, the two high-bay warehouses of the existing systems had to be modernized and optimally integrated into a comprehensive material flow concept in terms of conveyor technology," explains Bohlin. "On the other hand, we had to set up software that would enable coordinated process control across all warehouse areas." JYSK decided to replace the old system and implement the Wamas logistics software from SSI Schaefer. "The system was tailored to JYSK's requirements and connected to the overlaying SAP system," says Bohlin. To this end, the hardware of the existing systems was first brought up to the current state of the art in a retrofit project. "The conveyor technology controls and shelf operating devices had to be replaced and the conveyor technology partially upgraded. The performance of the two existing HBW was to be determined and incorporated into the Wamas process control system for optimum interaction with the new HBW," explains Gerhard Wolf, Project Manager at SSI Schaefer. In addition, the control of the AGVs, which take over the internal transportation in the flat building in front of the new high-bay warehouse, was integrated into the warehouse management system. This means that Wamas takes over the coordinated process control in all four warehouse areas of the distribution center: the three high-bay warehouse complexes together with conveyor technology and a flat storage area in an existing picking hall, from which large parts are picked.

Internationalization mastered

The internationalization of the flow of goods posed additional challenges. For example, items from different suppliers are delivered to JYSK in Sweden in and on different loading aids. Both Euro pallets and large pallets measuring up to 1,200 x 2,400 millimetres are in circulation at JYSK. In total, the JYSK distribution center now works with six different pallet, cage and platform sizes. "The order picking conveyor technology was originally only designed for Euro pallets," explains Wolf. "We have adjusted accordingly."

Wamas controls the distribution of the incoming goods pallets to the ten aisles of the new high-bay warehouse.

In order to be able to continue using the existing (order picking) conveyor technology, SSI Schaefer developed sub-pallets and installed one loading and one unloading station for the delivered large pallets. They are integrated into the conveyor technology in the front building of the new HBW. Another special feature: Despite the high throughput, no transfer cars are used for distributing and feeding the pallets for storage in the new high-bay warehouse. "We have implemented a solution here with corner transfer units and rotary roller conveyors," explains Wolf.

Goods are delivered to ten incoming goods gates. Four loading stations are set up for the automated handling of load carriers. Automatic collection, IT recording, contour and weight checks, automated labeling and transport securing of the pallets using automatic film wrappers take place at ident points on the conveyor system. This prepares the incoming goods for further internal material flow - unless Wamas sends them directly to the picking hall or outgoing goods, as is the case with fast-moving items.

The conveyor system guides the incoming goods pallets to one of two lifts. The vertical conveyors take the pallets to a transport bridge and from there via two further lifts to the transfer stations in the new high-bay warehouse. The conveyor technology to the two existing systems and the picking stations is connected to this. SSI Schaefer has modernized the picking stations themselves with a Pick by Light system, which ensures reliable order picking. Including the connection from the goods-in gates and to the goods-out lanes, the upstream conveyor technology with 189 roller conveyors and 325 chain conveyors covers a total length of 1.2 km. Ten energy-efficient Exyz two-mast storage and retrieval machines ensure optimized storage and retrieval processes in the new high-bay warehouse.

An empty pallet test lane for Euro pallets was set up in Nässjö specifically for handling empty pallets. The incoming pallets are tested using state-of-the-art pressure roller, tensile and sensor tests. "Once again, not only a convincing concept, but also an optimal project process and an impressive result," sums up Logistics Manager Annika Löfgren. "Separate flows of goods for incoming and outgoing goods as well as transparent processes designed for high throughput and coordinated throughout, controlled by a high-performance IT system: we are highly satisfied with the result."

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