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Warehouse system with box conveyors and euro pallet distribution

The main challenge presented to us by a company specializing in the distribution of automotive parts was the inefficiency of delivering and distributing pallets to the mezzanine level of their existing warehouse.

Additionally, the client faced a lack of buffer areas on the mezzanine floors.

Moreover, before automation, there was a need for close cooperation and full synchronization between the forklift operator and the personnel arranging the pallets within the warehouse structure.

To address these challenges, we provided our client with two parts of the warehouse - the entrance and exit sections.

On the entrance side, we implemented a multi-level storage system, a buffering and pallet transport system both vertically and horizontally, along with automated shuttle vehicles.

On the exit side, we installed a system for distributing goods in boxes and additional inspection stations.

Our task was to develop and implement a system that would efficiently deliver pallets to each level of the warehouse.

To achieve this, we introduced a buffer and transport system where the forklift operator's task is limited to placing the pallets in the entrance dock on level zero.

From there, the pallets are transported through conveyor systems and lifts, as directed by the superior Warehouse Management System (WMS), to the appropriate levels of the warehouse.

On each floor of the warehouse, we installed shuttle vehicles that distribute the pallets to buffer docks.

On the exit side of the system, employees pick up the goods from the warehouse shelves according to the received orders. They place the items in boxes, which are then transported to designated inspection areas through our implemented transport system.

By using scanners and exchanging data with the WMS, we continuously obtain information about the destination of each box, enabling reliable and efficient movement to the correct locations.

To ensure the smooth operation of the system, empty boxes are returned to the warehouse, thus completing the cycle.

The warehouse transport system is fully automated. This means that the operator places the box on the conveyor, and it reaches the designated inspection station without the need for intervention from other personnel.

By implementing this warehouse system, the client gained several benefits.

One of them is simplifying the process of delivering pallets to the appropriate warehouse level.

Additionally, we minimized delays and increased the loading efficiency of the warehouse system by using buffer elements.

We also reduced the involvement of employees in the handling process. Previously, the forklift operator had to oversee the entire loading process constantly, but now our system handles the movement of goods to the correct locations.

Furthermore, we contributed to reducing the delivery time of goods from the warehouse to the inspection stations.