The task was to create a logistics solution with considerably increased productivity without changing the mechanics, the satellite warehouse and the material handling equipment of the existing solution. Modernization was possible in controls, IT and the picking system. The old S5 controls needed to be replaced with S7 versions which allowed the use of a SAP direct link via Dematic Subdriver. The main task was to replace the proprietary warehouse management system with a modern SAP LES solution and implement more efficient procedures at the same time. The paper-based handling of pick orders was replaced by a paperless online picking solution with Pick-by-Voice introducing Vocollect Terminals and radio data transmission.

A special challenge was the climate condition in the warehouse for deep frozen goods. How do you apply a label at -25° Celsius? And how do you arrange tests, when there are regulations for maximum length of stay? Optimization of the satellite warehouse with eight and nine-deep storage locations was also carried out. Special storage and retrieval strategies, as well as reorganization needed to be established. A further feature was the integration of a Bina in-house development, a cage cart with variable shelves – the so called Shopomat. Besides these technical challenges there was the organisational task to modernize the installation whilst continuing operations as normal business, especially production outcome, could not be disturbed.

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