Knorr-Bremse: Optimizing Processes with a Small Parts Warehouse
Knorr-Bremse is the world’s leading manufacturer of braking systems and supplier of additional sub-systems for rail and commercial vehicles. To keep production at their site in Mödling, Austria flexible and economical, Knorr-Bremse implemented a new automation strategy for the entire plant. An important element of this strategy is an automated small parts warehouse, which efficiently covers various processes for production and supplies both their customers and subsidiaries with small parts.
Across the globe, Knorr-Bremse’s products play a major role in safety and energy efficiency on the rails as well as on the road. The company has around 29,500 employees at over 100 locations in more than 30 countries. Within the Knorr-Bremse group, Knorr-Bremse GmbH in Mödling is responsible for developing and manufacturing essential components for railway vehicle braking systems.
Automating different processes efficiently
The goal of the project was to use existing space more efficiently by optimizing spare parts storage and picking goods according to the goods-to-person principle. The new system had to provide higher storage density within the existing building while also performing functions such as picking, buffering and sequencing. Knorr-Bremse decided on the OSR Shuttle Evo automated small parts warehouse in combination with picking stations and a conveyor system mounted on the ceiling. The custom solution efficiently meets the requirements for Knorr-Bremse’s processes.
Knorr-Bremse’s requirements for the solution
For this location, we had very specific requirements, and therefore no off-the-rack solution would be sufficient. We needed a tailor-made system, both in terms of system performance and in terms of getting the most storage locations into the available existing space.
OSR Shuttle Evo: peak efficiency in production supply
The new automation solution shines with its simplicity, expandability and flexibility. At the center of the solution is the new OSR Shuttle Evo automated small parts warehouse, which supplies production and spare parts shipping as needed. It is also designed to provide space for future growth.
A conveyor system mounted on the ceiling connects the existing goods-in area with the automated warehouse and four Pick-it-Easy picking stations. The picking processes at the four identical work stations, which are also directly connected to goods-out, follow the same pattern. In the background, KNAPP’s KiSoft One software interfaces with SAP WM, keeping processes running smoothly.
A glimpse into the solution for Knorr-Bremse
Knorr-Bremse’s new automation solution went into operation in 2021. Since then, the performance of the company’s small parts warehouse has increased by a factor of three. The decisive factor was a custom-made automation concept that integrated all processes.
1 I Goods-in
Before goods are stored in the OSR Shuttle Evo, they are identified in SAP WM at decanting work stations and repacked into containers. Next, a label is printed and placed on the container where it can be easily read. On its way to the OSR Shuttle Evo, the container is scanned twice and allocated to an order. The storage process verifies that the maximum load per channel is not exceeded and follows an ABC storage strategy.
2 I Order start
SAP WM prioritizes orders, which are then sorted by KiSoft One and forwarded to the warehouse control system. The multi-purpose shuttle system differentiates between various order types. These include picking, buffering and sequencing orders for the in-house production supply as well as small part picking orders for shipping.
3 I Goods-to-person picking
The picking area consists of four Pick-it-Easy work stations, where items are picked according to the goods-to-person principle. Containers with the required items are retrieved from the OSR Shuttle Evo and supplied to the work stations at an ergonomic height, while the easyUse user interface and the Pick-to-Light system provide employees with the support they need during picking. A conveyor line supplies the work stations with empty containers. There, assembly kits for Knorr-Bremse’s own production, small parts to supply other Knorr-Bremse locations, and spare parts kits for end customers are picked.
4 I Sequenced preparation of production orders at the tugger train station
When mounting kits are required in the production cells, a request is booked. The buffered kits are brought to the tugger train station in sequence and positioned on the tugger train or in the roll container in the correct order. Transport to the production cells is either done manually or as a milk run.
5 I Shipping small part and spare part kits
As soon as picking has been completed, orders are conveyed to the packing area. Here, small parts from the OSR Shuttle Evo are merged with larger parts from the high-bay racks and are prepared for shipping.
Thanks to the new system, we could significantly improve the transit time between picking and shipping, increasing efficiency. Overall, we increased our performance in the small parts warehouse by a factor of three and significantly reduced costs.
How Knorr-Bremse benefits from the automated small parts warehouse
Simplicity
The system is highly standardized: The new OSR Shuttle Evo handles standard-sized containers, the work stations are identical, and the picking process always follows the same pattern. In the future, generic goods-out ramps will be connected to autonomous mobile robots or directly to a tugger train.
Expandability
The OSR Shuttle Evo allows space for future growth. When the expansion of the warehouse is complete, another eight rack levels will be available, providing an additional 7,000 storage locations. The picking performance at the four Pick-it-Easy work stations can also be increased even further.
Flexibility
The flexible system can react to changes along the entire value chain. Changing or adapting processes or orders is fast and easy, and its efficient empties management is also very flexible.
