Shuffle Mode: On! Best of the OSR Shuttle Evo

The OSR Shuttle promises complete flexibility in all your business cases. And our shuttles deliver on these promises. We have an ideal shuttle variant for every requirement: In the OSR Shuttle Evo 1D, one shuttle runs in each level of each rack line, offering particularly high speed and performance. The 2D variant, in which a shuttle changes aisles and can reach all lifts on the level, offers particularly high flexibility in process design. This variant also allows the warehouse performance and the number of storage locations to be separately scaled up as needed.

The OSR Shuttle at Getriebebau Nord includes three rack line systems with 44 levels in which trays and containers are stored double deep. Despite there being three aisles, there are exactly 44 shuttles in the warehouse, which continuously store and retrieve load carriers and transfer them to one of the two lifts. The 2D technology is what makes this all possible: Special aisles that cross the storage aisle are used by the shuttles to switch between aisles, thus allowing them to reach all the storage locations on the entire level.

Where space is at a premium or property costs are soaring, it makes sense to use existing warehouse space as efficiently as possible. Storing containers, trays or cartons using a multiple-deep strategy increases storage density, making the most effective use of space. In our OSR Shuttle Evo, all goods are equal when it comes to storage in the system. Stock and overstock are stored in the same system, giving you the benefit of maximum flexibility and optimum storage density.

The OSR Shuttle Evo running at Knorr-Bremse comprises two aisles and 18 levels. One aisle utilizes double-deep storage, and the other dynamic triple-deep storage. The storage capacity is about 16,000 locations for 600 by 400 mm (24 by 16 in) containers. Every level and rack line system contains one shuttle, which handles all storage and retrieval movements.

We will go with you into the future, no matter how your business develops. An OSR Shuttle Evo is designed to scale easily and to be adaptable to current and future performance needs. This means that the most economic version of the system is available for order fulfillment during each step of the expansion. Use all your available space profitably with the OSR Shuttle Evo. Scale it in length and width, and build it up to 30 meters (100 ft) high. When the time comes, you can expand with more shuttles or another aisle, so your system grows with your success.

For Luxottica, having the greatest possible flexibility and scalable performance in fulfillment is particularly important. Over a 7.5 hour shift, they pack more than 200,000 items and ship an average of 33,000 packages on a daily basis. The recipients of these packages include further distribution centers, stores (B2B), and end customers (B2C), which means the size of the shipments varies a great deal. They needed a scalable system to handle their volume of orders having so many different requirements.

The OSR Shuttle Evo covers a large range of warehouse processes. Storing, relocating, retrieving, buffering, sequencing orders and ensuring perfect item availability are just a few of the warehouse tasks our technologies can handle. To cover as many warehouse processes as possible, our OSR Shuttle Evo can be combined with further KNAPP technologies. Whether goods-to-person work stations, goods-to-robot picking, a solution with a pocket system or autonomous mobile robots – the OSR Shuttle Evo complements them all.

Magna Spiegelsysteme GmbH was searching for a logistics solution that would offer them the flexibility and value creation they needed. The answer was the OSR Shuttle Evo+, a combination of the proven storage system with Open Shuttles. While the OSR Shuttle Evo provides 20,000 storage locations, the six Open Shuttles supply the various production work stations with empty containers, which are then stored again in the OSR Shuttle Evo.

The OSR Shuttle Evo is much more than a small parts warehouse. Its intelligent control system streamlines the logistical processes in the warehouse. It stores, buffers, picks and supplies items at the right moment for picking. Two very important features include the creation of precise sequences and storing stock and overstock in one location. The OSR Shuttle handles all these processes independently.

The pharmacy wholesaler Novaltia supplies more than 1,000 pharmacies, where the end customer can pick up their medication within 2–3 hours. To make it happen, Novaltia implemented a warehouse featuring a 98 % degree of automation based on an all-in-shuttle solution. This shuttle warehouse fully automatically picks, buffers and sequences items while also replenishing the flow racks. Thanks to the strong performance of the OSR Shuttle, the entire warehouse can be operated with only six people per shift.

Renewing instead of replacing is gaining ground today, and this trend is also finding a foothold with the early generations of OSR Shuttles. Modernizing or modifying through retrofitting is often more economical and sustainable than building a brand new system. As a strong partner, we offer sophisticated modernization solutions to keep old systems up and running at maximum performance.

Service technicians follow a carefully thought-out retrofit process to minimize disruptions to operation during the renovations or expansions. The aisles are brought to a standstill one by one, allowing all the others to keep running. Another important aspect of the retrofit process is long-term KNAPP customer service, which includes the supply of original spare parts and the latest software updates.