DHL

Branches

  • spare parts logistics
  • retail / distribution
  • logistics service provider

Solutions

  • Radio Frequency/MDC
  • automated warehouse control
  • direct SAP-PLC data link
  • order picking warehouse control

SAP Product

  • SAP LES/WM
  • SAP TRM
  • SAP Console
  • SAP HUM
  • dez. LES

WAREHOUSE MODERNISATION WITH SAP LES (SAP LOGISTICS EXECUTION SYSTEM) AND SAP TRM (SAP TASK AND RESOURCE MANAGEMENT)

Now over 10 years old, the warehouse management and control systems at the three German DHL sites (Steinfurt, Oschatz und Rottenburg) offered only limited options in terms of extensibility, maintenance and backwards-compatibility.

Accordingly, DHL Exel Supply Chain decided to adopt a future-proof logistics platform based on the SAP software suite. With SAP LES/TRM, DHL Exel Supply Chain can map out all of its warehouse logistics processes, managing not only its manual storage but also its automated pallet warehouses and AS/RS for small parts.

DHL Exel Supply Chain now sees itself as superbly equipped to face the future, and is now planning to roll out the SAP LES/TRM solution at other sites.

DHL Exel Supply Chain is one of the world's leading providers of express, transport and logistics services.
The DHL Exel Supply Chain business unit offers end-to-end logistics solutions from a single source – particularly for the automotive, electronics, fashion, FMCG (fast-moving consumer goods), pharmaceuticals and telecoms materials segments – and implements these solutions along the entire supply chain.

In Germany, DHL Exel Supply Chain operates a number of highly-automated warehouse depots for its largest customer, a leading German telecommunications company. The three warehouse centres in Steinfurt, Oschatz and Rottenburg are used to store construction materials and spare parts for service technicians employed by the telecoms company.

As part of comprehensive consolidation work, improvements have been made to all operational logistics processes at these three sites.

DHL Exel's customer – a major German telecommunications company – uses SAP R/3 as its ERP system and requires full integration of DHL's systems with the SAP processes. For this reason, DHL Exel Supply Chain is already using SAP R/3 itself at a number of sites.

Since SAP R/3 has seen significant improvements over the years – and particularly in the area of Logistics Execution – dedicated warehouse process servers are no longer required from R/3 Release 4.7.

In 2004–2005, DHL Exel Supply Chain partnered with IGZ Logistics + IT to implement a future-proof solution based on the SAP software suite, to ensure that the existing warehouse systems at the company's Steinfurt, Oschatz and Rottenburg sites can now be managed using SAP LES (Logistics Execution System) and SAP TRM (SAP Task and Resource Management).

Decentralised SAP R/3 LES with TRM, Rel. 4.7 Logistics Execution System

  • with standard interface to the customer's SAP R/3 ERP system
  • ‚‚Multi-customer warehouse
  • ‚‚Handling Unit Management
  • GR packing station with packing recommendation based on packing instructions, bypass function, putaway labels
  • Use of SAP TRM (SAP Task and Resource Management) for RF stacker transfers (putaway, relocation, staging)
  • Stock removal simulation for planning
  • ‚‚Multi-order picking with packages valid for all delivery notes
  • ‚‚Real-time dynamic PLC control
  • Decentralised LES system in the data centre with site connectivity via leased line
  • SAP-PLC interfacing via 5 data concentrators (for small parts storage, HBW, conveyor system)
  • ‚‚PLC control for conveyor system and stacker cranes (Schneider Electric Quantum)
  • ‚‚25 PLC control units in total
  • TRM monitor for: Convey instructions (TOs and tasks), stacker crane status, communication point status
  • Alert monitor for error handling: Shelf full/shelf empty, re-planning, blocked aisle
  • Comprehensive logging (telegram traffic, SAP-PLC, system decision, etc.)
  • ‚‚WinCC visualisation system for graphical presentation of the overall facility
  • Two-tier SAP-PLC architecture (no need for middleware)
  • No deployment of custom-programmed modules, but fully-standardised technologies instead
  • Reductions in testing and commissioning times
  • Increases transparency and improves management of the overall system
  • TRM monitor for: Convey instructions (TOs and tasks), stacker crane status, communication point status
  • Alert monitor for error handling: Shelf full/shelf empty, re-planning, blocked aisle
  • Comprehensive logging (telegram traffic, SAP-PLC, system decision, etc.)
  • ‚‚WinCC visualisation system for graphical presentation of the overall facility
  • Harmonisation of the IT-driven logistics system architecture
  • Real-time communication with PLC console
  • Powerful PLC simulation with monitoring
  • Reduces outlay for maintenance, service and troubleshooting
  • Maximum process flexibility

SAP TRM (SAP Task + Resource Management): Control of AS/RS for small parts

  • Putaway/removal strategy and dynamic bin management entirely within SAP
  • Pick + Pack handling at the picking centres (touchscreen interface)
  • Quantity shortage handling with automated replanning

 


SAP TRM (SAP Task + Resource Management): HBW control

  • Whole pallet removal and picking
  • Negative picking
  • Picking container recommendation via geo data
  • Multi-order picking (number of delivery notes can be parameterised)

 


SAP TRM (SAP Task + Resource Management): Conveyor system control

  • Fully-automated ID point recording
  • Container travel optimisation across all picking centres
  • Autom. shipment sorting per tour using buffer lanes and sort/distribute lanes
Key Facts

LOCATION

  • Steinfurt

 

AS/RS for small parts

  • 14,800 tray bays
  • Trays with up to 12 totes
  • ‚‚7 aisles, 7 autom. stacker cranes
  • ‚‚360 trays/h via conveyor system
  • ‚‚55 interleaving ops/h per stacker crane

 

AUTOM. PALLET HBW

  • 16,500 bays
  • 5 aisles, 5 autom. stacker cranes
  • ‚‚27 interleaving ops/h via stacker crane
  • ‚‚160 pallets/h via conveyor system

 

MANUAL STORAGE AREAS

  • 7,566 sqm storage space
  • ‚‚5 RF MDCs in storage for fast-moving articles
  • 5 RF MDCs for bulk storage
  • ‚‚2 RF MDCs for transportation tasks
  • Special storage, hazardous materials, etc.

 

PICKING CENTRES

  • 4 centres for HBW (28 pallets/h)
  • ‚‚6 centres for small parts storage (50 trays/h)

 

TOTE CONVEYOR SYSTEM

  • 333 totes/h

 

TECHNICAL DATA

  • 1,150 3-phase motors
  • ‚‚10 DC motors
  • ‚‚52 scanners
  • ‚‚950 retro-reflective photoelectric sensors
  • ‚‚25 PLC control units

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