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Automatic transport and storage system for boxes

Our client, specializing in the import and distribution of automotive parts, faced the challenge of efficiently managing returns and goods deliveries in their logistics center.

To address this, we designed and built an efficient and automated high-storage warehouse.

During the concept development phase, we received a specification for the technical solution, which we further refined to meet the investor's requirements and needs.

The result was an automated system consisting of a high-storage warehouse housing nearly 11 thousand containers.

The warehouse is served by 30 automated shuttle-type vehicles, 4 mini-loads, and 4 high-capacity vertical conveyors.

The system also includes conveyor lines for transporting containers and two picking stations with triple slots. Additionally, we implemented an error station with a weighing system to determine the filling percentage of the containers. The project was complemented with areas for receiving new goods and zones for fast and efficient order picking.

During the design phase, we used FlexSim software to model the logistics processes of the warehouse.

We created a communication interface between the client's Warehouse Management System (WMS) and Iconics SCADA, which is responsible for the allocation and flow of containers within the warehouse system.

Returned goods from the store network and new goods from manufacturers are registered in the system and placed in containers at the receiving area, where 30 inspection stations are located. Subsequently, they are transported via roller and belt conveyors to the warehouse.

On different floors of the warehouse, the containers are distributed using vertical conveyors, picked up by shuttle vehicles, and placed in free locations within the double-deep storage system.

Finally, the containers are retrieved from the warehouse and transported to their respective stations. The maximum measured throughput of the system is 1200 containers entering and leaving the warehouse per hour.

The investor can seamlessly continue using their WMS, with the high-storage warehouse appearing as a new location.

An essential feature for the client was the openness of the system and the use of commercially available components that are widely accessible on the market.

Our solutions do not employ black-box-type control with dedicated electronics, enabling the client to diagnose and service the warehouse independently without long downtimes.

The main benefit the client received was a two to threefold increase in order picking efficiency.

Employees handling order picking in the older parts of the warehouse could process 80 to 150 products per hour.

In our warehouse, a single worker completes 300 items per hour.