© SSI Schäfer

Optimum processes, especially for small parts
In mid-2017, SSI Schaefer handed over a system for largely automated logistics processes with store-specific picking and provision. The focus: increasing capacity and efficiency, especially in the small parts segment. "Small parts are stocked exclusively in Krefeld and make up around 50 percent of the product range in stock," says Buschmann, referring to Fressnapf's article structure: "It is not very homogeneous, consisting in the non-food segment, for example, of accessories such as leashes, toys or nestable food bowls. In the food segment, our product range also includes snacks and special food in various variants and container sizes." Accordingly, SSI Schaefer's system concept was tailored to optimum storage and efficient picking processes for both bagged goods and small parts. "Where it makes economic sense, we have automated the processes to reduce the workload on our employees," says Buschmann. "SSI Schaefer's concept with the different picking areas for different order requirements is ideally designed for the varying turnover rates of the diversified range of items in our EDC."

Complex processes holistically embedded
SSI Schaefer set up a multi-user warehouse complex directly connected to the existing warehouse area using conveyor technology. "At the same time, the complex processes were embedded in a holistic material flow," explains Matthias Häußler, project manager at SSI Schaefer. For example, the incoming goods area was built over with a two-storey steel platform construction. On level zero, the incoming goods delivered on pallets are processed, recorded and transferred to storage in accordance with the warehouse management system (WMS). After collection, forklift trucks first take the incoming goods to a ten-aisle manual narrow-aisle warehouse. There, 5,840 pallet spaces are set up for temporary storage. It is used to replenish the AKL and to provide full pallets. A racking system with around 300 pallet spaces has also been set up for the direct supply of promotional goods.

Forklifts transfer the pallets
For the automated processes for preparing the pallets at the setup workstations, forklifts transfer the pallets to the pallet conveyor system on the lower level of the goods-in platform. It guides the pallets on the platform construction above the incoming goods area to two transfer carriages. These operate transfer trolleys, which in turn load 24 lifters. These load and unload the twelve depalletizing stations set up on the upper level of the goods-in platform, with each workstation being operated by two lifters. The packs are separated at the depalletizing stations. The stations are equipped with a three-level conveyor system for this purpose: Empty containers are fed in on the middle level and the target containers are removed on the lower level. A belt conveyor on the top level is used to dispose of old cartons. The conveyor system finally transports the target containers with the separated articles or packs to the miniload or directly to the eight Schäfer Carousel Systems (SCS) for picking.

AKL divided into functional areas
The AKL is divided into two storage blocks according to functional areas: Three aisles with just under 35,000 container storage locations serve as a supply warehouse. The four aisles of the order picking miniload are supplied from here, where more than 22,300 container storage locations are installed for the fast-moving items. A total of seven Schäfer Miniload Crane (SMC) storage and retrieval machines are used for storage and retrieval. Picking stations with flow channels are installed in the aisles of the order picking miniload on the lowest level, which are loaded directly from the back of the miniload. The stations are divided into individual stations and equipped with a pick-by-light system (PBL). "This subdivision enables picking with short walking distances," explains project manager Häußler. An automatic carton erector provides the cartons, which each receive a routing label on two sides at the start of the order.

The target cartons with the labels are transferred to the circulating conveyor system via a vertical conveyor. Integrated scanning technology interacts with the WMS to ensure that the cartons stop at the stations responsible for order picking. There, the pick faces of the PBL system inform the employees about the access compartment and the number of items to be picked. Once the removal has been acknowledged, the conveyor line takes the cartons to the next station. Finally, after picking, the shipping cartons are removed, sealed by an automatic carton sealer to reduce their volume and, after a weight check, labeled with the parcel label by an applicator. The conveyor system then transports the cartons directly to the roller conveyors in the shipping area or to one of the two shipping SCSs specially designed for handling cartons for interim storage. If required, the shipping cartons from the different picking areas are brought together and temporarily stored there.

System can also be used for e-commerce
In addition to the order picking DCS, Fressnapf has more than 10,000 additional storage locations for medium to slow-moving items in eight other order picking SCSs. These are spread over two floors and each level is equipped with one pick-to-tote workstation (PTT) for dynamic picking processes. Here, the source containers are delivered to the employees in sequence and up to seven orders are picked directly into the shipping cartons in parallel. Once picking is complete, the shipping cartons are also automatically removed, sealed to reduce volume and labeled with the parcel label. As an option, the system can also be used for e-commerce and offers, among other things, the possibility of discharging shipping cartons directly after completion at one of the six CEP workstations provided for this purpose via a spiral conveyor directly onto the specially designed gravity roller conveyor in the outgoing goods area. The conveyor system transports order items for store delivery to a downstream consolidation buffer for order consolidation. This has more than 8,700 storage locations for short-term interim storage and provision for palletizing according to route and store. At the same time, the order cartons can be discharged directly onto the 50 dispatch lanes in the outgoing goods area for manual palletizing. This is where the orders are consolidated with the palletized large-volume items from the other storage areas.

More efficiency, productivity and customer service
"The system from SSI Schaefer ensures the required availability and a high cycle rate for order picking," summarizes Fressnapf Logistics Manager Christian Buschmann. "As a result, we have significantly increased efficiency, productivity and customer service and have been able to sustainably improve our cost structure with features such as volume-optimized shipping. We are particularly pleased that the ergonomically designed workstations have made the working environment much more comfortable for our employees."

The logistics service provider SSI Schaefer
The SSI Schaefer Group is a solution provider of modular storage and logistics systems. The company employs around 10,500 people at its international headquarters in Neunkirchen, as well as in around 70 operating companies worldwide and at more than eight production sites in Germany and abroad. Spread across six continents, SSI Schaefer develops concepts and solutions for its customers' industries. The company plans, designs and produces systems for setting up warehouses, factories, workshops and offices, manual and automatic storage, conveying, picking and sorting systems as well as solutions for waste technology and recycling. SSI Schaefer has developed into one of the largest providers of release-ready software for internal material flow. More than 1,100 IT experts develop high-performance applications. The software portfolio with Wamas and SAP covers all processes from warehouse to material flow management. At the same time, SSI Schaefer optimizes the productivity and work performance of its customers with its own solutions and also creates the opportunity to actively manage the warehouse by measuring and evaluating with the help of KPIs.