Gerolsteiner

Branches

  • grocery
  • retail / distribution

Solutions

  • Radio Frequency/MDC
  • batch tracing
  • RFID
  • transmission/loading
  • Produktionssteuerung
  • IGZ Best Practices

SAP Product

  • SAP LES/WM
  • SAP Console
  • SAP HUM
  • SAP MII
  • SAP PCO

STACKER POSITIONING WITH RFID

Gerolsteiner is Germany's No. 1 in the mineral water market and is now also an innovation leader in terms of its warehouse logistics.

For its warehouse management and pallet tracking, Gerolsteiner decided to use a solution combining SAP LES (SAP Logistics Execution System), RFID geolocation and automated scanning functionality on pallet approach.

This has ensured the automated and complete transparency of container movements, as well as meeting the requirements of EU 178/2002 – and all without sacrificing efficiency.

Gerolsteiner Brunnen GmbH & Co. KG holds the number one spot in the German table water market and is also Germany's largest mineral water exporter, shipping its products to 25 countries.

Gerolsteiner table waters are filled directly at the source – Gerolstein in the Eifel Mountains – and may therefore be advertised as "natural mineral waters". Only in this way can the original purity be guaranteed without adulteration or contamination.

Gerolsteiner markets its products to all relevant mineral water segments in a wide variety of packaging formats. Strongly focused on consumer needs, the company from the Eifel Mountains aims to meet them by exploiting its innovative strengths to the utmost. Products such as Gerolsteiner Sparkling, Gerolsteiner Still, Gerolsteiner Natural, Apple Squash, Fit, Lemon Fresh and St Gero Spa Water are daily favourites with consumers.

If, like Gerolsteiner, you load up to 600 HGVs in a single day in seasonal peak periods, you don't have the time to assign each pallet to a sales order with hand scanners.

Due to the requirements for the batch-level traceability of containers (EU Reg. 178/2002), Gerolsteiner was looking for a solution that would guarantee traceability while simultaneously safeguarding warehouse throughput.

The decision was made to use an automated stacker positioning system, in conjunction with the automated identification of pallets via scanning. With the combination of SAP LES (SAP Logistics Execution System), RFID geolocation and automated scanning, Gerolsteiner has fully achieved its objectives.

  • SAP R/3 LES with WM, Rel. 4.6c Logistics Execution System (master LES)
  • Rollout of SAP Warehouse Management (SAP WM), replacement of paper-based warehouse management
  • Documentation of goods flow via polling of stacker movements (RFID geolocation)
  • Documentation in SAP WM (SAP Warehouse Management) about pallets that can be consolidated into removal blocks
  • Direct confirmation of pallet blocks picked up in SAP WM (SAP Warehouse Mangement)
  • Online communication via SAP Console (forklift terminals, handhelds)
  • Master SAP LES (SAP Logistics Execution System)
  • RFID geolocation (transponders in factory floors, RFID antennae on underside of stackers)
  • Stacker touchscreen terminals and autom. SSCC scan when approaching pallets (ultrasound sensor)
  • Future-proof thanks to the SAP software suite (no WMS subsystems)
  • Full transparency for all material flows in the warehouse
  • Comprehensive batch management with Handling Unit Management
  • Meets requirements of EU Regulation 178/2002 without sacrificing productivity
  • Online posting of stock movements
  • User-friendly screens for acknowledging pallet removal blocks
  • Quality improvements thanks to electronic loading checks
  • Time savings thanks to automated scanning operations
  • 100% read rate (even with stacker speeds of 25 km/h or wet factory floors)

SAP WM (SAP Warehouse Management) SAP Console: RADIO FREQUENCY

  • Stackers with graphical terminals (SAP GUI)
  • Handhelds with text-based terminals
  • Pick + Pack handling with case picking
  • Transponder-assisted pallet grouping functions
  • Block-wise pallet removal

 

SAP HUM (SAP Handling Unit Management): BATCH TRACEABILITY

  • Fully-autom. pallet identification via SICK-brand scanners mounted on the stackers
  • System-driven plant stock transfer processes
  • Transponder-supported loading bay management
  • Autom. loading checks via gate PC with laser scanner

 

SAP WM (SAP Warehouse Management): STACKER POSITIONING

  • Pallet identification of transfer points from production via transponder
  • Multi-pallet handling (4x, 6x) plus identification
  • Automated storage bin ID via transponder (RFID)
Key Facts

LOCATION
2 premises in Gerolstein


KEY FIGURES

  • Annual sales of 7 million hl
  • 9,000 pallets handled per day
  • 50,000 pallet bays in total
  • Up to 400 pallets per block lane
  • Up to 600 HGVs per day (GI)
  • 2,500 glass tubes with RFID transponders in factory floors
  • 15 production collection points
  • Approx. 30 stackers (4x, 6x stackers)
  • Approx. 10 handhelds

 

MILESTONES

  • Hardware selection, trials during May/June 2004
  • Planning phase June 2004 – August 2004
  • Implementation September 2004 – December 2004
  • Testing and pilot runs, January 2005 – March 2005
  • Go-live: April 2005

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