With the project "Value Stream-Optimised Factory Structure Planning: Coffee Machines", WMF AG is realigning its entire production, including production logistics, to match value stream criteria.
To date, manual processes have been efficiently modelled within the parts warehouse. WMF optimised its production supply processes by constructing an automated warehouse for small parts: this facility uses the Goods-to-Person picking principle to maximise stock quality and achieve further effects due to streamlining operations. For other types of warehouses, WMF already uses the SAP Logistics Execution System (SAP LES).
Together with IGZ it studied its options for operating the new AS/RS exclusively with the SAP LES (SAP Logistics Execution System) software suite. The recommendation was to integrate the AS/RS for small parts with the factory's SAP ERP (SAP Enterprise Resource Planning) system. Today, SAP LES (SAP Logistics Execution System) and its embedded SAP Task and Resource Management (SAP TRM) material flow control run on the core SAP ERP (SAP Enterprise-Resource-Planning) process layer without any additional interfaces.
The result: Cost savings, optimum process flexibility and independence from proprietary systems.
Headquartered in Geislingen an der Steige, Württembergische Metallwarenfabrik AG – WMF AG for short – is one of the world's leading manufacturers of tableware and kitchen products.
With a company history stretching back 150 years, the cutlery, tableware and oven-to-table goods, kitchen utensils, cookware and coffee machines produced to WMF's stringent standards have now become indispensable to well-managed households, restaurants and hotel establishments worldwide. Products from WMF impressively combine function and durability while being aesthetically pleasing and of an uncompromising quality. For decades, WMF has enjoyed outstanding success – also at an international level – in producing and marketing WMF-branded all-in-one coffee makers that fulfil even the most demanding requirements.
Manufacturing for this successful product group is based at WMF's main factory at Geislingen an der Steige. Worldwide, WMF employs numerous people, with the total Group workforce – including Silit-Werke, Alfi, Auerhahn Bestecke, W.F. Kaiser & Co.
In order to further increase the productivity of the coffee machine assemblies and exploit the additional rationalisation potential, WMF has opted for greater automation in the supply/transfer processes.
The central component of the future assembly supply system will be a fully-automated small parts storage system with computer-driven container delivery to upstream task, picking and defect-checking centres. From an IT perspective, the goal was to avoid setting up proprietary subsystems when integrating small parts storage into the future production supply processes.
A concise high-level analysis completed in collaboration with IGZ revealed that the SAP Logistics Execution System (SAP LES) already in active use in Geislingen/Steige would provide ideal support for operating fully-automated small parts storage. Thanks to the core integration approach that was then implemented, i.e. operating SAP LES (SAP Logistics Execution System) on the SAP ERP (SAP Enterprise-Resource-Planning) system, extra controller layers – as required by non-SAP solutions – could be avoided. Material flow control is handled by the SAP Task and Resource Management (SAP TRM) SAP material flow system integrated into SAP LES (SAP Logistics Execution System).
This is an optimal solution to the objective of creating an interface-free and lean SAP IT solution. During implementation, IGZ provided the WMF IT team with support in expanding their expertise with SAP LES (Logistics Execution System) and SAP TRM (SAP Task and Resource Management). Today, WMF is now capable of operating the SAP LES (Logistics Execution System) and SAP TRM (SAP Task and Resource Management) solution independently with no outside help.
- SAP LES (SAP Logistics Execution Management) und SAP TRM (SAP Task and Resource Management) integration on central SAP ERP (SAP Enterprise-Resource-Planning) system (SAP ERP ECC 6.0)
- Implementation of PLC simulation for SAP SCE to verify overall system performance and for dry runs of linkage
- Direct material flow control via SAP TRM (SAP Task and Resource Management)
- Complete process mapping (incoming goods issue/goods receipt, replenishment strategies, tray creation, picking, etc.) in SAP LES (SAP Logistics Execution System)
- Receipt printer (e.g. delivery notes), label printer, etc.
- SAP Empties/Storage Unit Management
- 3 PLCs of the type Siemens SIMATIC S7
- SAP TRM monitoring, fault monitoring, capacity monitoring
- Real-time telegram traffic between PLC level and SAP TRM (SAP Task and Resource Management)
- Simplification of the IT architecture via interface-free integration of SAP LES (SAP Logistics Execution System) and SAP TRM (SAP Task and Resource Management) with SAP ERP (SAP Enterprise-Resource-Planning) (centralised integration scenario)
- Independence from proprietary systems and external IT partners
- Cost reduction via elimination of maintenance contracts for external systems
- Maximum investment protection via use of the SAP SCE software suite
- Standalone process adaptations/extensions by WMF IT (expansion SAP LES/TRM know-how)
- Deep integration of the process logic in the SAP SCE software suite (direct coupling with automated warehousing technology)
Together with IGZ we could introduce SAP LES (SAP Logistics Execution Management) and SAP TRM (SAP Task and Resource Management) on time and budget. In all phases of the project we got to know our IT project partner as competent and reliable.
SAP TRM (SAP Task + Resource Management):
- Communication point and priority-controlled material flows with SAP LES/TRM
- Interleaved stacker cranes with 4-deep automated small parts storage assignment
- Management of tray container assignment in SAP LES/TRM
- ID point functionality with weight verification
SAP LES (SAP Logistics Execution System) Picking: Picking
- SAP LES-controlled, properly sequenced container/tray service at Goods-to-Person picking stations
- Real-time accounting for parts withdrawals in the SAP ERP system
- Graphical picking dialog with automated printing of the pick label (Kanban)
SAP LES (SAP Logistics Execution System) Production Supply: Supply to assembly
- Demand- and consumption-driven (Kanban) material staging
- Replenishment for spare parts warehouse and other storage types
- SAP LES real-time posting to SAP production order
- Individual selection/bundling screen for release order parts
- FIFO with manual override
- WMF headquarters and main plant in Geislingen an der Steige
- Container rack with 4,284 bay channels for the following assignments (maximum values):
- 8,568 containers (600x400)
- 17,136 containers (300x400)
- 34,272 containers (300x200) on trays
- 4-shelf-deep storage
- 2 rack aisles, each with one track-bound unit (stacker crane)
- Each stacker crane with 4x load handling capacity
- 2 picking stations based on the Goods to Person principle (GtP)
- 2 tray/container storage centres
- 1 defect handling centre
- Pre-zone conveyor system
- Tray and container transport
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