Storage/Staging: Fully automated pallet AS/RS optimizes processes for industrial distributor

Rösler Oberflächentechnik GmbH is a leading international manufacturer of finishing and shot blasting equipment, and related consumables and machines for deburring, descaling, sanding, polishing, grinding and more. The family-owned company, established in 1933, was faced with a growing business and ever more exacting market requirements. After constructing a new automated storage and retrieval system (AS/RS), the company increased storage capacity and service levels.

“Our task was to bring together these warehouses in the best possible way,” says Marcus Henkel, head of central organization at Rösler. “We had to optimize the space required by the previous solution so that we could gain more room for potential growth.”
The new solution includes a three-aisle pallet AS/RS that is 90 meters long and 26 meters high with a total of 7,731 pallet storage locations with single-deep storage. The AS/RS takes care of inbound and outbound orders. The pallets are weighed, and the data is stored in the warehouse management system. There are four pick stations. The conveyor system and the warehouse and the shipping area is connected with a double transverse shuttle car.

The company handles different types of pallets and materials so that heavy machinery parts or liquid chemicals can be stored in 1,000-liter intermediate bulk containers that are all stocked in the same warehouse. The ability of the AS/RS to be controlled so that there are no tilting and lateral movements during travel was very important.

“Truck traffic in storage and retrieval has been reduced almost to zero,” Henkel says. “Now the automatic conveyor system takes care of these tasks. In addition, a goods-to-person approach ensures that the goods can be made ready for transport faster than before and at a much better pace. We have seen a huge leap in performance.

The company is working toward an absolute zero-error rate in order picking, and Henkel reports that new staff required only a short familiarization process after the project launch.

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