Greenfield approach on a 20,000 sqm meadow.
Lots of materials require lots of storage spaces. Lots of storage spaces require lots of external systems. At least if you want to make processes as efficient as possible. After an intense consultation and planning phase, SSI Cuby shuttles, SSI SMC, semi-automatic narrow-aisle trucks from Toyota for the high-rack warehouse, put-to-light systems and A-frames were integrated into the hardware infrastructure of both distribution centers. In addition, picking processes were to be made more intuitive using handheld devices. This initial situation resulted in completely new automation options and work processes, which first had to be defined, then tested and finally implemented. A greenfield approach that was challenging for both DocMorris stakeholders and status C. Especially because the new distribution center was still under construction at the start of the project and all process simulations and mass tests had to be meticulously prepared and tested "live on site" in distribution center 1. The collaboration in agile sprints and the sometimes months-long continuous deployments of the status C experts on site made this massive task possible in the first place.
Let there be light (-barrier).
At the heart of an optimal material flow is storage and retrieval - in the case of DocMorris with the help of over 5 km of conveyor technology, amongst other things. After redefining the processes, order totes can now be filled more efficiently using pick-by-light and hand-scanner order pickers or directly from the A-Frame with several orders at the same time or optionally skip stations before they finally reach their destination - the packing stations. Here, the containers are then deconsolidated and prepared for dispatch. Each workstation in the warehouse also has customer-specific Fiori apps. For example, all 70 packing and control stations are equipped with intuitive user interfaces for incoming and outgoing materials, which were developed individually with the warehouse employees. While employees are instructed accordingly via the large warehouse monitor at the workstations, light barriers in the picking bays verify not only the packaging material but also the goods inside. This always ensures a 100% control and therefore a crucial safeguard for DocMorris in the material flow.