The automotive sector is a common symbol of modernity. Car factories are pioneers in applying different innovative solutions in the field of automatics. Such solutions are not only connected with production, but also with distribution. Today we will check how Audi and Skoda do it.
During the premiere of the new Audi A8, the company presented an innovative solution automating its internal transport. It has been working for a few months in the factory in Ingolstadt, and to be more precise in its logistic center providing auto parts to assembly workplaces functioning under the complete knock-down (CKD) scheme.
The biggest challenges included: high diversity of packages for structural elements (12 different types) and integration of automated guided vehicles (AGV) with a complex IT system used by Audi.
In 2015, we conducted a market research to find companies which could carry out this task. Considering the technology offered, including the integration of internal logistics with our IT system and solutions for safe processing of different containers, often weighing more than a tonne, stored at the height exceeding 5 m, we have decided to cooperate with Still and Dematic Egemin,” says Stefan Meier, who is in charge of logistics planning in Audi.
The system is based on two automated and programmed FM-X reach truck lifts, transporting containers from high-bay racks onto 24 packing lines. A pilot project conducted for several months showed that such solution, on the one hand, enables increasing storage density and, on the other hand, ensures appropriate efficiency of internal transport. Parts delivered to packing zones with reach trucks are then picked up and sent to Brazil, China, India and Mexico where they are used to produce models of A3, A4, A6 and Q5 series for the distribution in regional markets.
Automated distribution of spare parts
Distribution – yet of a different nature – has been also automated in Skoda Part Center in Mlada Boleslav. In this case, it was about spare parts.
Distribution of spare parts is characterized by strong fluctuations of demand (depending e.g. on changes in weather). For instance, the decrease of temperature may result in the increase of demand for accumulators. The aftermarket typically is accompanied by numerous methods of delivery. A group of retail customers (auto repair shops), even ordering small quantities, can require fast delivery, possibly same day delivery.
This type of logistics is connected with the agile system ensuring quick response to external changes and high-quality, reliable delivery.
The centre in Mlada Boleslav (one of the three central warehouses of the company) is equipped with intralogistics technologies, starting from simple block storage of bulk products with different types of pallet racks to carousel racks such as paternoster for small goods.
The automated high storage warehouse contains nearly 200 thousand items. It processes thousands of order items a day.
This warehouse is designed to support a narrow aisle pallet warehouse, block stacking warehouse and automated mini-load warehouse for small parts.
The warehouse installation is 42 meters high and 100 meters long. It can contain 30 thousand carriers. The building has a form of a silo, which means that both walls and roof are integrated with the rack structure. Automated stacker cranes move between the racks (11 aisles). They are equipped with adjustable forks for transporting load units of different sizes.
Photo: Skoda
The whole warehouse is divided into two zones. There is a classic ABC storage area on the one side from which orders are picked up and the reserve area on the other side. Any pallet movements in the warehouse, entry and exit zones are conducted automatically.
“Pick by light” system helping employees
The warehouse supports also conventional pallet conveyors (chain and roller conveyors) and the monorail system (consisting of unmanned automated rail-guided vehicles with their own drive). The most important element of the system is the rail which provides power to the vehicles and guides them in the proper direction. Each vehicle is equipped with chain conveyors for picking up and putting pallets onto the conveyors.
From the automated warehouse, the material can be transported directly to the exit zone (to send pallets to a wholesale shop) or the order picking zone. The latter consists of two levels.
Each of the levels has five picking stations, and the process is supported by a “pick by light” system (the light directs the worker to the appropriate storage location), enabling the capacity of over 200 pallets per hour.
The automation control of the warehouse is integrated with SAP ERP system steering the entire material flow (it is responsible, among others, for steering a manual warehouse and automated mini load warehouse).
Photo: Skoda