The average processing time for an order was reduced from four days to one day. In addition to the optimization of internal processes, customer service has also been further improved. MiniTec also offers its customers tailor-made solutions for warehouse logistics.

Minitec started out over 30 years ago as a supplier of a modular system with aluminum profiles and linear technology. Since then, MiniTec has developed into a technology company specializing in automation, conveyor technology, workplace systems and assembly technology. The experience gained in the realization of customer requirements was incorporated into the design of the new small parts warehouse with automatic picking and integrated conveyor technology.

The static storage system with shelving racks had reached its limits over time. There was a theoretical capacity of 30,000 storage bins on the floor space of 3,600 square meters, but only around 1/3 of this could be used. The upper rows of shelves could only be reached by ladder or lifting equipment, which was neither ergonomic nor efficient. The picking performance of 500 items and 100 orders per day could no longer be increased with the man-to-goods system and single-order picking.

From goods receipt to packaging

The new system consists of a combination of four storage lifts with a usable height of nine meters and a bulk goods warehouse, each with its own station. All stations in the system are automatically connected to MiniTec's conveyor technology. The system includes goods receipt, order picking, provision for packaging and return transportation of the empty containers. Depending on the task, driven roller conveyors for high unit weights, belt conveyors for ascending and descending sections and toothed belt conveyors for feeding the picking stations and the pneumatic transfer stations are used. The entire transport system was implemented from MiniTec's "Conveyor Technology" catalog range. A total of 55 electric motors are in use. The system is controlled by a state-of-the-art PLC programmed by MiniTec software engineers.

Warehouse logistics is now paperless. The orders come from the ERP system and are "married" to a picking container when the order is started. For this purpose, the entire order with all items is transferred to a barcode on the outside of the container. The totes with the order information are automatically transported to the correct station. There are five picking stations at each station, so that ten orders can be picked at the same time. The goods are automatically transported on trays from the warehouse lift to the employee. A pick-to-light system and a laser beam indicate the products to be picked and the quantity. All the employee has to do is confirm that the bin has been released and the system then automatically navigates through the system to the next station or issuing point. 18 barcode scanners detect the crates at each switch and decide on the direction of transportation.

To ensure process reliability, the warehouse management system was also equipped with new software. The warehouse management system (WMS) communicates bidirectionally with the ERP system. Stock changes are taken into account in the system without delay, ensuring up-to-date stock control and replenishment management at all times. Even missing stock is taken into account and picked directly onto the order via a bypass control system when goods are received later. The integrated batch management allows goods to be stored in a chaotic manner with the advantage of making optimum use of storage space. And last-but-not-least, the continuous comparison of target and actual stock levels provides the basis for permanent stocktaking. The annual inventory is completed at the touch of a button.

With the new storage system, the efficiency of the warehouse has been improved many times over, while at the same time drastically reducing the error rate. The average throughput time for an order has been reduced from four days to one day. A key criterion for the investment was also the improvement in work safety, the reduction in workload and the associated increase in employee satisfaction.

MiniTec's product range covers the entire field of conveyor technology. Depending on the requirements, heavy-duty roller conveyors, double belt conveyors, belt conveyors or link chain conveyors are used. The new UMS system is available for linking production machines, in which the return transport of empty pallets takes place underneath the conveyor section to save space. With the WF 3000 spiral conveyor, heights of up to five meters can be bridged. Thanks to the conveyor's innovative reversing technology, it can also be used as a workpiece storage system for feeding machine tools.