- automated warehouse control
- Radio Frequency/MDC
- order picking warehouse control
- PLC control technology
- batch tracing
- production supply
- direct SAP-PLC data link
- general contractor
- logistics planning
- SAP EWM
- SAP MFS
- IGZ Automation
IGZ has delivered top quality - the availability of the complete system is 100%!
Bernd Kohl | Head of Production, Division Industrial technology
ZF Friedrichshafen AG
Thanks to our IGZ and SAP EWM we have succeeded in securing our parts supply on a long-term basis.
Daniel Biefeld | Project Manager
ZF Friedrichshafen AG
IGZ REALISES NEW ASSEMBLY WAREHOUSE FOR ZF PASSAU AS A SINGLE PROVIDER!
The industrial technology division of the ZF Friedrichshafen technology group has centralised its logistics and automated its processes. As a result of this, it was possible to increase capacity 11 times over.
In the course of the restructuring, the front part of a more than 30-year-old high-bay warehouse was demolished and the remaining infrastructure was gradually modernised. A further central function holder in the “assembly performance centre” is an automatic small parts warehouse with 44,000 container storage locations, which directly serves production supply. Since August 2016, the entire system solution has been managed using SAP EWM and monitored using SAP MFS.
When Ferdinand von Zeppelin, a pioneer of the aviation industry, founded a “gears factory” in 1915, he laid the foundation for a modern billion-dollar company with around 230 locations worldwide. The Industrial Engineering Division is coordinated from Passau and all activities for “off the road” applications are bundled in ZF Friedrichshafen AG. Gearboxes and axles for agricultural and construction machinery, drive technology for forklifts, as well as rail and special vehicles are developed and produced. In addition, the division is responsible for global marine and aerospace propulsion, as well as the manufacture of gearboxes for wind power plants and industrial propulsion systems.
“To ensure the supply of parts in the long term, we had to put our logistics on an entirely new footing,” says ZF project manager Daniel Biefeld. The intention was to dissolve the dispatch warehouses and to create increased dynamism in logistics processing. The focus here was on the replenishment and reaction times. IGZ Automation GmbH from Falkenberg/Opf. supported the ambitious project as a development and implementation partner. The scope of services included, on the one hand, the implementation of SAP EWM as the standard solution for warehouse management including SAP MFS for material flow control. At the same time, IGZ, as general contractor under the lead management of Alfred Meyer, IGZ Managing Director, was responsible for the IGZ general contractor business and the retrofitting of the high-bay warehouse, as well as the new construction of the 4-aisle automatic small parts warehouse.
“With the old warehouse technology, we were able to store and remove 55 small load carriers and 55 large load carriers per hour,” says Daniel Biefeld. With the support of SAP EWM, today, the total for the high-bay warehouse is 160 and 550 for the automated small-parts warehouse “We have increased the storage capacity ten times over.” The throughput time in goods inward has been reduced from 14 to 3 hours and the recovery time of goods in the assembly performance centre has been cut from 24 to 6 hours.
The reaction time of logistics to triggered requirement reports is now just a quarter of an hour. At the same time, space was created in the assembly hall as a result of a reduced amount of work in progress, which can now be used productively in other ways.
This means that ZF Friedrichshafen AG is well positioned at the Passau location from a logistical perspective for the next 10 to 15 years, also because the installed system solution is scalable and expandable. At the same time, the decision for SAP EWM marks an important milestone in the history of ZF Friedrichshafen. This is the first IT solution to be used throughout the group. This makes the division a pioneer in the ZF logistics world.
The extensive restructuring of the logistics structure has received several ZF EXCELLENCE AWARDS within the ZF Group.
GOODS OUTWARD KEY FIGURES
- Sending out of up to 600 KLTs/hour.
- Reduction in the replenishment time for production supplies from 24 to 4 hours.
- Availability of the entire plant at a level of almost 100 %.
- Storage performance increased 11 times over.
- Reduction from three to two shift operation.
Retrofit autom. HRL
- 9.000 storage spaces
- 5 lanes, 5 RBGs (MIAS)
- Conveyor technology: 180 Pal./h
New construction AKL
- 50,000 storage locations
- 4 lanes, 4 RBGs (TGW)
- Container loop: 1,000 containers/h