Global truck brand fasttracking with Westfalia
IVECO Magirus AG based in Amsterdam represents Fiat's commercial vehicle arm. With approx. 33,400 employees and a market share of 18.7% in Western Europe, IVECO is now the second largest manufacturer of HGVs on the continent. Westfalia Logistics Services has installed a future-proof modernisation concept for the German production site in Ulm. Among other things, this involved the use of Savanna.NET, Westfalia's flexible and modular software solution.
The Ulm logistics centre of IVECO Magirus AG has been in operation for over 30 years. In order to bring the system into line with increased demands and ensure a smooth material flow, an analysis of the current situation was performed and revealed the following optimisation requirements:
The units of the integrated 9-aisle single-bay storage system showed a very high level of wear and tear.
The automatic materials handling equipment operates with special carrier pallets made of metal, which are moved along extremely narrow runners. This considerably reduced the options for using standardised components and called for a customised solution.
The electrical overhead materials handling system in the preparatory zone was no longer able to meet the logistical demands satisfactorily.
In the future, the storage system will also be used by IVECO Magirus Brandschutztechnik GmbH. This meant that a high-bay storage system with two-client capabilities was required.
It was necessary to integrate a picking station in the preparatory zone, also supporting two-client capabilities. At the same time a clear distinction between the two clients had to be made. While IVECO only stores full pallets, Magirus Brandschutztechnik GmbH picks its products so that part pallets are temporarily available.
Westfalia faced up to the challenge with a complete solution concept
Given the requirements, the Westfalia team defined the following objectives: Increased performance in the preparatory zone, utilisation and management of the warehouse by two clients and implementation of an emergency strategy with any failure of one of the client areas.
Modification of the storage technology
At the heart of the new preparatory zone are two traversing bogies, each equipped with a telescopic fork. These bogies are responsible for the storage and retrieval of items at their positions in the storage system, as well as at the picking stations and transfer positions in the warehouse. The structural modifications were carried out by Westfalia Logistics Services according to the motto: "As little as possible, as much as necessary". For this reason, three delivery stations were installed for each company (some of which also operate as temporary picking positions) and one pallet receiving station. In addition, Westfalia implemented a weight and contour check system at the receiving points. This ensures that only defect-free pallets are delivered.
Client capability for Magirus Brandschutz and emergency strategy
In the storage area for IVECO Magirus Brandschutztechnik, Westfalia equipped the new picking stations with scissor lifts for raising and lowering the pallets to ensure more ergonomic working. The emergency strategy is solved by the traversing bogies: In the event of a fault, the defective bogie moves into a parking position. The fault can then be rectified without interrupting normal operation. Another traversing bogie is then responsible for storage and retrieval.
Integrated system control with Savanna.NET
Westfalia's software Savanna.NET has been used for central control of the IVECO logistics system. It directs the flow of materials and order picking processes while separating the two clients. Thanks to its modular structure, the software can be adapted to the individual problems on site and integrated in the processes without difficulty. A further benefit: The software offers continuous and dynamic growth along with future requirements.
Summary
Westfalia's experts completed the entire modernisation project in a mere five months. All defined objectives were achieved in close cooperation with the IVECO project team. "We were delighted that Westfalia Logistics Services was able to complete the project without any complications in such a short time. The project management stuck to its schedule exactly, right through to the handover", confirmed Peter Ingedult, project manager for IVECO Magirus AG, in praise of the successful modernisation project.
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