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  • SCA_France_SattStore
    from the other store Production is performed in one site Factory South From Factory South pallets labelled with an EAN128 label are delivered into Warehouse South on two conveyors Both conveyors are equipped with a Logo Pak barcode labelling station and barcode reader and registration of the pallets is performed completely automatically Goods coming this way are always stored in Warehouse South The pallets are stored into the warehouse using Trains i e a row of pallets pushed by a forklift truck SattStore calculates the size of the trains dynamically keeping in mind a number of parameters Maximum train size Maximum train weight Maximum available free pallet places on the deposit locations The trains can exist of more then 20 pallets which are handled in one transport When output is requested it is possible to perform picking in advance during the night before delivery The picked goods are parked in the warehouse until the truck has arrived When the truck arrives several strategies are activated to optimize the truck loading like The journey loading principle is activated which means that the truck is loaded in reverse order in which it should be unloaded Shortest driving distance for the mobile trucks Optimal spreading of the truck drivers regarding the workload Due to SattStore external storage can be reduced dramatically Because of this and several other advantages the return on investment is calculated on one year To give an impression of the weekly performance the following averages are achieved 19 000 pallets received per week 7 days 24 hours 19 000 pallets delivered per week 5 days 16 hours over 400 shipments Special functions Train handling Controlled transfers between the two physical separated warehouses Location selection considering stacking height of the articles on the pallet and physical limitation in the warehouse Consider

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/sca_france_sattstore (2016-04-26)
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  • Glud_Marstrand_SattStore
    til at løfte den daglige drift med bedre kvalitet til færre omkostninger læs færre ressourcer systemet skulle tilføre ledelsen og organisationen et validt datagrundlag for drifts og kapacitetsstyringen af lageret samt ruteoptimering af plukkearbejdet systemet skulle tilføre ledelsen et effektivt analyseværktøj til at løbende at vurdere lagerets præstationer systemet skulle tilvejebringe online og realtids informationer om lagerstatus Indkøringsudfordringer Implementeringen af det nye WMS foregik i august 2006 men Glud Marstrand løb hurtigt ind i udfordringer med at få systemet til at understøtte lagerdriften Glud Marstrands lager er både et råvare og et færdigvarelager idet lageret både forsyner produktionen med metal samt plastmaterialer og forsyner kunderne med færdigvarer Lageret anvender endvidere kaotisk dybdestabling hvor man blander varenumre og FIFO status i rækkerne simpelthen fordi man ikke har kvadratmetre til at gøre det anderledes Det giver et mere kompleks vareflow og gjorde installeringen af SattStore hos Glud Marstrand til en lidt mere kompleks opgave end sædvanlig Behov for kvalificeret projektledelse Problemerne ledte til at Glud Marstrand ansatte en nyuddannet produktionsingeniør og cand merc som skulle overtage ansvaret for implementeringen af systemet Nicki Toft Hansen startede 1 oktober 2006 som materialestyringschef med den opgave at få det nye WMS til at fungere efter hensigten Forstå systemet Løsningen på problemerne bestod i at forstå systemet og de algoritmer som ligger til grund for indlagringen og palleplaceringen Vi kører fx efter kaoslager princip og FIFO altså First In First Out SattStore understøttede ikke umiddelbart vores form for kaotisk dybdestabling hvor vi blandetr varenumre og FIFO status og der forekom derfor nogle pallebyt som ikke var hensigtsmæssige Et andet eksempel var at nogle af vores låg til konservesdåser har en karenstid på to døgn før de må gå videre i produktionssystemet Det kunne vi ikke umiddelbart få SattStore til at tage højde for fortæller Nicki Toft Hansen IT baseret lagerstyring af kaotisk dybdestabling med blandede varenumre og FIFO status er uhyre kompliceret Det har krævet udvikling af meget avancerede algoritmer der kan tage højde for hvilken plads indlagringen af en palle skal foregå på samt hvilken palle plukkeren skal vælge Det var en krævende udfordring som vi er meget tilfredse med er lykkedes så godt som det er fortæller adm direktør Dan Hellström Consafe Logistics A S Projektleder ud på lagergulvet Nicki Toft Hansen placerede sig selv midt ude på lageret så han var så tæt på lagergulvet som muligt og så gik han ellers i gang med systematisk at undersøge hvordan systemet understøttede den daglige lagerstyring Jeg blev nødt til at tage det udgangspunkt at være loyal over for systemet og finde frem til hvordan systemet og vores hverdag bedre kunne mødes Det lykkedes også efter nogle hektiske måneder hvor Consafe Logistics programmører arbejdede hårdt på at justere de ting jeg fandt frem til og hvor vi også ændrede på nogle af vores arbejdsrutiner så de passede bedre til systemet Bedre produktivitet og færre fejl I dag står truckførerne på lageret selv for den daglige planlægning af arbejdet antallet af fejl er reduceret så markant

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/glud_marstrand_sattstore (2016-04-26)
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  • Canon_SattStore
    after a thoroughly put out ABC analysis on everything which is small and tiny it appeared that a new approach would give better results We now use the miniload for stocking mid and slow movers and put away the fast movers in the new shelves in the new building where we have some 40 000 stock locations he says Where also in the mean time all floors are in use because at street level there are the flow racks and on the second and third floor the shelf layers with picking stock is placed The old building host the miniload New miniload An extra problem occurred when the miniload starts to show old age behavior We knew it would come because it already was ten years of age the Canon Manager says So what ever happened we needed a new management and control system for the miniload Mr Van Wezel states and that appeared to be an adventure by itself It was however the combined expertise of Daifuku and Consafe Logistics that brought the solution At first the miniload was expanded with a new rack supplied by Nedcon and a new crane supplied by Daifuku Also new hardware and software to manage the new solution was implemented At that moment we operated with two separated control systems which both communicate with the WMS It appeared that SattStore had no problem at all with this phenomenon At second all crates with supplies have been moved from the old racks to the new ones but by hand because this was done faster than by crane operations Than the old crane has been dismantled and replaced by a new one which has been connected to the new control system These actions were repeated at weekends for continuing operations until all cranes were replaced Than the new control systems worked all together with SattStore without any problems Workflow The miniload operates with 35 000 transport and storage crates with different capacities A large number of crates stores 4 different articles SKU s Stock Keeping Units and a smaller number holds ten SKU s Supplying is done directly from the inbound area The flow racks store up to 3 000 SKU s and the pallet racks have capacity for 6 200 pallets The miniload even has an overload capacity of about 7 000 crate locations which is a result of the adding of a new rack and extra crane This leads to a more flexible storage capacity than has been in the old more static situation The Canon European Spare Parts Center delivers her clients on a 24 hours basis The Direct Dealer Delivery task makes sure that dealers in all European countries receive an item ordered on day one before 5 00 p m the next day This is about small packages The Canon National Sales Organisations NSO in the various countries act as distribution center as well and receive their goods in item level box level or pallet level depending to the item

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/canon_sattstore (2016-04-26)
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  • Optimera_ExtendERP
    largest company groups with activities in over 50 countries The company has implemented Extend ERP from Consafe Logistics in order to promote further development This mobile application solution makes stock control more efficient at the same time as routines and work related to goods reception and goods counting are simplified In addition the solution gives better control of stock and goods balances in warehouses and shops Extend ERP has been developed to meet the strictest requirements for stock routines traceability and delivery quality The mobile solution supplied by Consafe Logistics is integrated into the building material chain s existing ERP system Movex and has enhanced Optimera s stock and logistics support packages by a number of new facilities Among other things this means wireless data acquisition and mobile information transfer Using hand held terminals Consafe Logistics system contributes to increased efficiency in several links of the chain from the warehouse goods reception stock taking and picking to the shop customer service Consafe Logistics has also installed a local radio network WLAN at 25 of Optimera s shops in Norway Using Extend ERP it is possible to register all stock and shop transactions in real time When the data is only

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/optimera_extenderp (2016-04-26)
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  • Telstar_SattStore_NL
    three experts Verhagen We had our doubts whether the users would appreciate this picking method wearing a headset but since we involved them in the project at an early stage they too were very enthusiastic It turned out at that time that Consafe would also be able to supply the voice picking technology The WMS supplier had already successfully implemented voice picking at food producer Arla Foods in Denmark The advantage of Consafe s technology was the fact that Telstar would not need a separate middleware system Middleware is an additional software layer that the three previously consulted experts in automatic identification would have had to implement to allow the WMS to communicate with the headsets An additional software layer like that would make the project much more difficult Verhagen explains Consafe s voice picking solution was available as a fully integrated module for SattStore Colour coded batch picking Telstar used the opportunity of the voice picking implementation to scrutinise the warehouse processes This resulted in major changes to the order picking strategies The most important change was the transition to batch picking Before warehouse staff would go around the entire warehouse for a single customer Now they pick orders for four customers at a time To this end Telstar bought carts that fit four plastic bins The picking process starts at one of the many print locations at the DC An employee need only mention the number of the printer via the headset and the printer will provide four dispatch labels one for each customer The labels are pasted onto the four empty bins and the actual picking can begin SattStore gives the picking orders for these four customers via the headsets in the order determined by the route The WMS gives the picking location and the employee goes to that location Once there the employee confirms the picking location by giving the so called check digit This is a verification number stated in very small print underneath the barcode on the location label We did this on purpose to make sure that the order picker is in fact at the right picking location Verhagen explains One risk of batch picking is picked goods ending up in the wrong customer bin In order to prevent this Telstar and Consafe together came up with a colour coded system The four positions on the order picking carts each have their own colour red green yellow and blue The dispatch labels that come out of the printer already state which customer is assigned which colour SattStore not only gives the number of items to be picked for each picking order but also the colour of the bin in which the goods are to be placed Verhagen We deliberately chose the most contrasting colours Order overlap Productivity for batch picking is determined for a large part by the extent to which the various orders match Batch picking would not be very sensible if the WMS were to combine four orders that each have

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/telstar_sattstore_nl (2016-04-26)
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  • Elektroskandia_Astro
    large discrepancies in actual and assumed stocks We needed to reduce picking faults and be more efficient in driving down costs Upgraded DC in Oslo Norway The heart of Elektroskandia s logistics system is their DC in Oslo This is where Consafe Logistics has helped by upgrading logistics routines and implementing Astro WMS together with voice picking and truck mounted Trafficom computers Optimising picking rounds Elektroskandia and Consafe Logistics have developed a system that maximises picking rounds Previously order flows come in but the company never knew how many goods needed to be picked so trucks have often been half full during the picking round Today Astro holds back picking rounds that are incomplete When sufficient parts of an order are available to maximise the picking round Astro releases the order to picking This has increased efficiency and led to a 25 reduction in manpower costs within the truck pick handling area The system has increased total warehouse efficiency by about 10 Astro now gives us statistics for everything s ays Alf Akselsen We work with greater speed fewer picking faults and the ability to handle increased numbers volumes per day with the same staff Contact since 1998 We first evaluated Consafe Logistics in 1998 when we held a pre qualification process for several WMS suppliers Consafe Logistics was chosen but work was put on hold when Hagermayer bought our company comments Alf Akselsen We resumed pre qualification talks after a few years where Consafe Logistics were forced to compete with global logistics suppliers We again chose Consafe Logistics because they offered several advantages They have a proven system for Automation and a fully integrated system that brought together Astro WMS voice picking and the Centiro transport management system Consafe Logistics local presence also made communication much easier Unique voice control system Elektroskandia has implemented a unique combination of paternoster machine and automatic lifts with voice control The system gives operators full handsfree control of all functions This has led to much faster and more accurate picking increased safety and much better ergonomics as operators can concentrate of all their tasks Quickly achieved goals Elektroskandia achieved its goal of at least 10 increased picking accuracy within the first year The main benefit from automating our warehouse is being able to drastically reduce discrepancy between physical and theoretical stock comments Alf Akselsen Wall to wall accounting is now gone as it is performed by Astro Zero accounts saved the company half a million Norwegian kronor overnight We also halved the number of wrong picks The more orders that come in the more efficient the system becomes Now the company has 10 more order lines yet handles these increased volumes using the same personnel Improved working hours Elektroskandia places tough requirements for lead times between order cut off and when the first shipment leaves the building All order lines are picked and dispatched on the same day 45 of orders are received between 2 00 pm and 4 00 pm so the

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/elektroskandia_astro (2016-04-26)
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  • Arvid Nilsson
    picking Today we generate picking orders directly in Astro WMS Astro WMS then tells the picker exactly what to pack and which boxes to pack them into Put this article in this box etc Pickers can pack up to 24 different boxes on one tour of the warehouse says Morten Stenshøj IT Project Manager However it made sense for them to evaluate the SAP WMS solution considering their new ERP system based on SAP In the beginning we were very interested in using SAP WMS as it made sense to implement one complete solution s ays Morten Morten and his colleagues visited several other companies to see the SAP WMS in operation We saw lots of possibilities especially in the ability to plug n play the module directly into the SAP ERP system What we found was that the system lacked what we needed in certain critical issues that were already facilitated in Astro WMS Using SAP they would make several separate journeys taking far more time and making picking more labour intensive s ays Morten Morten pointed out that SAP WMS is a good solution but it did not fit Arvid Nilsson s specific needs Needed a future proof ERP system The company has been using an in house system for the last 25 years that was developed by the present IT manager We still maintain this system but as demands grow we saw the need to buy a large standard ERP system that would fit all our needs s ays Morten It was a huge task for a company of Arvid Nilsson s size to keep a proprietary system running being very expensive to develop upgrades for different purposes A good example is e commerce where the larger standard systems already have solutions available as plug ins eliminating the need for proprietary programming The benefit of buying from major ERP system suppliers is that they have ready to use functionality that can be purchased and simply plugged in Our strategy was to buy an Off the Shelf system that would meet all our present and future business needs We chose SAP after evaluating 4 different systems and suppliers says Morten No retraining needed A huge advantage for updating the current Astro WMS instead of changing to another WMS provider was that the company would not have to completely retrain all its staff Astro WMS is a proven system that people are pleased with and can handle easily The only training costs would be to learn the new functions in upgrades With SAP the staff would have to learn all over again Already integrated with Centiro Another big plus for Astro WMS was that it was already integrated into the Centiro Transport Management System Arvid Nilsson uses Centiro for transport management shipments and order tracking streamlining the company s transport flows Upgrade of Astro WMS Once we had made our decision to go with Consafe Logistics we visited them and talked about the new upgrade and discussed the implementation

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/arvid_nilsson (2016-04-26)
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  • Sanistal Astro
    sig Grundtanken i den forbedringskultur er at enhver fejl er en mulighed for at forbedre sig Den form for kultur kommer ikke af sig selv det kræver masser af træning anerkendende og coachende ledelse samt massiv medarbejderinvolvering Vi er i dag nået langt på den rejse og det mener vi er nøglen til at styre en drift igennem en krise Man får ikke succes med krisestyring hvis man blot skærer blindt fortæller Claus Hjerrild 2 skridt foran Adfærd og ledelse er nøglen Saniståls centrallager i Billund har siden 2008 implementeret en lang række leantiltag og principper såsom Value Stream Mapping 5S flow tavlemøder målstyring standarder problemløsningstavler Kaizen Blitz etc Leanarbejdet er foregået under fællestitlen 2 skridt foran som signalerer at centrallageret hele tiden skal være på forkant med fejl og forbedringer Leanarbejdet har fokuseret på tre områder nemlig det operationelle ledelse og holdninger Det er ikke vanskeligt at gennemføre en Value Stream Mapping eller 5S den store barriere er implementering af nye holdninger og adfærd Vi arbejder med isbjergsmodellen hvor alt det synlige ved lean som fx tavler og værktøjer er over vandoverfladen mens alt det der virkelig gør en forskel som ledelse indstilling og adfærd befinder sig i det skjulte under vandoverfladen Succes med lean afhænger helt af at det lykkedes at få ordentlig fat i alt det skjulte og få skabt forandringer på disse områder Det er svært men det er her de store og vedvarende gevinster gemmer sig fortæller Claus Hjerrild der tidligere har arbejdet med leanimplementeringer i en række Danfoss virksomheder WMS er grundbasen Centrallageret i Billund har været gennem en turbulent tid og implementeringen af WMS er foregået i en række faser med idriftsættelse af en hal ad gangen Efterhånden som vi har fået implementeret WMS giver it styringen os et stærkt grundlag for at reducere lagerværdi og forbedre kvalitet fortæller Claus Hjerrild En kompleks lagerudfordring Saniståls centrallager i Billund lagrer som nævnt 96 000 varenumre der fordeler sig på alt fra småbitte plastdupper til trægulve og O ringe til kæmpestore kloakbrønde og 6 meter lange jernstænger Lageret skal altså være i stand til både at håndtere meget store mængder ordrer og meget forskelligartede ordrer Lageret omfatter både pallereoler hyldepluk flow racks blokstabling og ikke mindst 42 lagerautomater hvor plukning foregår med Voiceteknologi Plukker mange ordrer på én gang Det nye WMS betyder at Sanistål er gået fra papirbaseret pluk til realtids plukning i såkaldte plukkebølger Det betyder at Sanistål populært sagt ikke plukker én ordre ad gangen men plukker til mange ordrer på én gang og plukker direkte i forsendelsesenheden Det giver en bedre udnyttelse af plukkeressourcerne og en højere plukkekvalitet WMS foretager automatisk en beregning af volumen og vægt på ordren og udvælger derefter den rette kassetype eller boks Den avancerede teknik går under navnet bokskalkulering Sanistål og Consafe Logistics der leverer Astro WMS har undervejs erfaret at volumen og vægt ikke er tilstrækkelige parametre til at foretage den rette bokskalkulering men at det i Saniståls tilfælde også er nødvendigt at tage højde

    Original URL path: http://www.consafelogistics.dk/in-practice/case%20studies/sanistal_astro (2016-04-26)
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