Maxdata Würselen, Germany
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RFID and pick-to-light optimize built-to-order process
Maxdata Würselen, Germany
The customer:
Maxdata is one of the biggest European hardware assemblers. Its product and service portfolio focuses on the requirements of commercial users. Maxdata produces servers, PCs and Notebooks, that carry the brand Maxdata and displays und VDUs that carry the brand Belinea. Maxdata sells exclusively through indirect sales channels. Production is based on the BTO principle.
The challenge:
Maxdata asked Dematic to replace the existing integrated solution for picking at the production site at Würselen, Germany. This included the replacement of the outdated conveyor systems and pick-to-light systems by new technology from Dematic. In addition to the prime objective to enlarge existing capacity, Dematic got incharge of the improvement of the entire material flow concept, the picking quality and the acceleration of related processes. On top, the integration of the PTL solution with SAP had to be improved significantly. The orders from SAP to the PTL system were transmitted via batch jobs before. Verifications for the picking processes were missing. As the picking bins were already labeled with RFID tags for requirements of the assembly line, it was evident to use this technology as well for picking and preassembly.
The solution:
Dematic created a complete new Order Fulfillment Solution based on its own conveyor technology BK-10. For the picking areas a pick & pass system with stations was implemented. Picking bins can be routed intoor pass picking stations at need. "Faster" picking bins can get ahead of „slower" bins. This reduces traffic congestions. Currently the picking bins are dispatched into two levels via vertical conveyors. A third level could be added later.
The picking system seen from the perspective of SAP is a bonded storage area. The material that is requested in the orders are transferred from SAP to the Order Fulfillment System (OFS), that breaks down the orders to picking channels or pallet storage locations respectively. The preassembly starts with the assignment of orders to picking bins. The serial number is written on to the RFID tag on the bin.
The PLC receives a telegram with the first picking station to be approached and optional alternative targets. At each routing-out of a station the PLC receives a telegram with the next destination and optional alternative destinations.
At each check point the bin tag is read by an RFID reader, so the PLC can decide if the bin has to be routed into a station or if it has to pass this station. The optimization goal is to perform as many picks at a station as possible. Whenever a picking bin leaves a picking station the OFS has to decide if the previously planned route is still optimal. If the picking bin approached an alternative station where not all required material was available, an additional station has to be approached. Vice versa it’s possible that planned stops at stations can be omitted.
The new pick-to-light system from Dematic with about 2,000 displays was completely integrated with SAP in order to allow direct online verification by SAP.
Implementation:
The new material flow concept accelerated the picking processes significantly. Existing bottlenecks within the material flow were eliminated. The usage of RFID tags for the identification of bins at check points has proven it‘s value. The identification is very fast, contact free and highly reliable. The new pick-to-light system has proven it‘s value as well. Not only the picking bins, but also the replenishment bins for the picking channels are transported automatically to the stations. The replenishment bins carry RFID tags as well and are read at the replenishment stations.
Customer benefits:
