Polar opts for bespoke spare parts logistics
Polar, the world's leading manufacturer of high-quality paper cutting machines, has implemented a complete tray storage concept from Westfalia Storage Systems including order picking at its main plant in Hofheim. The new logistics centre will be responsible for organising the dispatch of spare parts all around the world. Products from the machine factory founded by Adolf Mohr in 1906 are renowned throughout the world in the graphic arts industry. Each year Plant I in Hofheim produces 2,300 high-speed cutters and 1,500 peripheral devices for downstream processes after cutting. In Germany, Polar employs around 500 staff, who are however only a fraction of its global workforce of 4000 based at over 200 branches and in 170 countries.
Strong commitment ensures optimum services
According to Polar's Managing Director, Alfred Henschel, the company has invested some EUR 50 million in new buildings and conversion work over the last nine years in order to make the site future-proof. In this context, the foundations were laid for a new 1,450 m² warehouse for spare parts in the autumn of 2005. This building was designed for the storage and retrieval of spare parts for direct deliveries across the globe. This was preceded by restructuring of the spare parts distribution system, which, until a few years previously, involved the indirect shipping of goods via Polar's global branches. After conversion to the new method, the volume of outgoing orders was increased by a factor of 3, reaching approx. 150 consignments daily. The customer-orientated technology from Westfalia Storage Systems installed in the new warehouse played a major part in this improved efficiency. According to company management, logistical effort was noticeably reduced, so leading to enormous cost savings for Polar.
Using Westfalia's expertise to meet new demands
In order to ensure the worldwide availability of spare parts as guaranteed by Polar, a total of around 20,000 items are stored in Hofheim for up to 25 years. The components are moved around and stored as tray loads, something which calls for special system specifications with regard to load handling and load management.
The cutting machine experts found the right partner in Westfalia Storage Systems. Thanks to the Westfalia MiniLoad System, an in-house development, the company had already acquired considerable expertise and experience in handling special load carriers. Westfalia's experts were able to use their skills to optimum effect when designing a tray storage system for Polar. By the time the agreement was signed, the scope of the project included an automatic spare parts storage system with 3354 tray positions and a forklift-operated pallet storage system with 1050 positions for Euro pallets.
Customised capacity and mobility for Polar trays
The completely redesigned spare parts storage and distribution centre switched to two-shift operation in March 2006. It features two storage blocks each with 41 levels and 41 storage channels, measuring 29.6 m in length, 4.11 m in width and 11.8 m in height. Every single-depth channel provides one pallet position with a tray size of 1306 or 1290 x 610 mm. The storage and retrieval vehicle used moves the load carriers with a travelling speed of 240 m/min and a lifting speed of 120 m/min. The travelling speed of the Westfalia Satellite® is max. 80 m/min. Under these conditions, it is possible to move 174 single-tray loads or 87 double loads, with a maximum loading of 300 kg each.
Additional materials handling technology and order picking
In-house transport between production and warehouse, and between warehouse and dispatch, is carried out using two gravity roller conveyors, which cover an overall length of 11 m. 8 chain conveyors with lifting are also in operation. A runner and contour checking system ensures a smooth material flow. At the picking point, an integral weighing station and laser pointer provide for the precise acquisition of all data, which is then available online to the dispatch department.
Summary
The new Westfalia spare parts storage and order picking system is ideally tailored to Polar's special storage requirements. Thanks to significant increases in productivity, the renowned company is able to satisfy its global service commitments far more quickly and with greater customer orientation.
