Smoothing path to growth

Firm to roll out significant automated investment to support growth predictions and has appointed Witron as implementation partner

Automotive parts supplier, Ferdinand Bilstein will expand its warehouse capacities at the logistics centre in Ennepetal, with the design and installation contract awarded to Witron.

"Based on enormously increased sales volumes, and due to the successful expansion in other countries and market segments, we already require the additional logistics resources originally planned to be used in 2015," says Febi logistics manager Frank Boecker. "As a result of the very good experiences we had with Witron's OPS (Order Picking System) and MPS (Module Picking System) in terms of cost-efficiency, performance, quality, flexibility, and ergonomics, we immediately made the decision to implement these same solutions for our future expansion." In order to maintain high service levels for national and international customers, the system in Ennepetal will be expanded from its current 36,000 SKUs to a future target of up to 105,000 SKUs.

The tote picking system OPS will be expanded by 16 additional pick workstations (26 in total), by nine additional storage aisles (19 in total), and 90,000 locations (190,000 in total). The MPS system for the automated storage and picking of heavy and bulky parts will receive eight additional pick workstations (20 in total), four new storage aisles (11 in total), and 22,200 pallet locations (61,500 in total). The automated product packing department will be expanded by six workstations (21 in total).

A new 4-aisle automated high bay warehouse will stand 28 metres and hold 10,250 pallet locations. This dispatch buffer will provide pallets in the proper timing and sequence for trailer loading, using far less floor space than today's manual buffering process. Moreover, the dispatch buffer will also be used to store and supply packaging material, thereby freeing up capacity in the MPS pallet high bay warehouse and increasing performance in the MPS zones.

The expansion during ongoing operation will be performed in two steps.

The MPS module will start productive use in October 2012. The new OPS areas and the dispatch warehouse will follow at the beginning of 2014.

"The investment into the new warehouse will strengthen Febi's international position and increase attractiveness for customers and partners.

It is also an important pillar for the development of new markets, the generation of competitive advantages, and long-term job security in the region," explains Boecker.