BENNING specializes in reliable modular power supplies for industries where production reliability is critical. Its logistics center plays a key role in maintaining that reliability because any disruption can directly affect customer production. After 12 years of operation, essential operational systems at the logistics center were outdated architectures, which increased operational risk.

With modernization becoming critical, BENNING needed a partner that could trust to understand the existing operation, reduce transition risk, and design a path forward without disrupting production. BENNING evaluated providers by the reality of its logistics center not simply being a support function, but a key to production continuity.

To keep material flow stable, secure, and adaptable, BENNING chose a comprehensive modernization guided by deep operational insight and a practical understanding of how the facility needed to perform over time.

BENNING faced structural challenges that had accumulated over many years. Outdated control mechanisms and software were critical constraints. The three stacker cranes ran on legacy systems lacking modern IT security and stability, while core processing units were discontinued and no longer available. Any defect threatened to bring production to an unacceptable standstill.

The warehouse management software was based on an older architecture that could no longer be updated. Employees found processes cumbersome and wished for a more intuitive interface to improve real-time inventory visibility and control. Without modernization, increasing risks of failure loomed. Comprehensive renewal was not only a technical upgrade, but a necessary investment in long-term stability, planning reliability, and operational resilience.

The modernization process identified specific operational outcomes: resilience, availability, security, and easier future maintenance. Updating the warehouse management architecture was central to that approach. The updated architecture connects processes more effectively across the facility, providing throughput reliability and real-time inventory visibility and control. And the improved flow and increased efficiency create a more resource-conscious, sustainable operation.

Dematic redesigned the control architecture to improve resilience and capacity. Discontinued components were replaced with globally supported PLC control technology, and stacker cranes received new controllers. The result is more stable communication, better diagnostic capabilities, and a noticeably lower susceptibility to malfunctions.

Dematic developed a precise implementation concept with short time windows to protect facility availability and production continuity. The transition proceeded smoothly, resulting in a more secure operation that can adapt to meet future requirements.

BENNING now benefits from significantly more stable and adaptable logistics operations for its production environment. The modernized software supports more efficient processes and a more intuitive user experience, helping employees access information directly. This reduces errors, accelerates workflows, and improves day-to-day reliability. Fewer errors and less rework increase operational efficiency.

Modernized control elements deliver higher performance and minimize outage risks. With globally available components, spare parts supply is more reliably secured. IT security is strengthened by the current operating systems.

Logistics now fully plays its role as the reliable backbone of production. Processes with easier maintenance make future updates simpler to integrate and protect the value of the investment.

A continuous improvement process has now begun: The new system allows for integrating smart functions and data-driven analyses. This approach gives BENNING greater operational transparency and stronger control over material flow with a foundation for the continued development of the logistical infrastructure.