Manufacturing companies: When things get stuck in the warehouse, production comes to a standstill. (Part 2/2)

Digital warehouse processes ensure a smooth flow of materials between the warehouse and production. They support employees before things become critical.

When everything is running smoothly, you don't notice anything. But as soon as a component is missing, a storage location remains empty or transportation comes to a standstill, you notice it immediately. Intralogistics is the sparring partner of production. And it is under constant strain - for example, because deliveries arrive too late, a wide variety of kits have to be coordinated and there are different types of warehouse to manage.

In the first part, we showed how digital solutions can reliably supply production, facilitate traceability and support quality checks. Now we take a closer look at the next three hurdles.

Challenge 4: Time-critical deliveries and bottlenecks

Whether seasonal peaks, raw material bottlenecks or just-in-time production - supply chains are under pressure. Even a missing component can paralyze processes. Some companies only realize this when it is too late. The bottleneck is there, the customer is waiting and the production manager is annoyed.

Smart solution: real-time inventory management & tracking

Our warehouse management software knows every stock item. It shows what is available, what is missing and what needs to go out immediately. Critical deliveries are prioritized and stock levels are always up to date. Those who use real-time data act instead of just reacting and recognize impending bottlenecks at an early stage. Those who rely on manual processes risk standstill. Time-critical deliveries are no exception - they are part of everyday life. With smart inventory management and clear processes, logistics runs smoothly and does not become a bottleneck.

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Challenge 5: Kit building (set building)

Many products consist of sets or assemblies. Various components have to come together just-in-time - either in stock or to order. Manufacturing companies offer a large selection with many configurations. Customers appreciate this variety. The process needs clear structures to ensure that individual assembly works. Well-organized kit creation makes the wide range of variants manageable.

Two approaches to kit formation:
1. Kit-to-order (KtO): The company only assembles kits after receiving an order.
2. Kit-to-Stock (KtS): The company produces kits in advance, stores them and keeps them ready for use.

Smart solution: parts list management for kit creation

Our software manages both approaches - kit-to-order and kit-to-stock. It manages parts lists, creates picking lists and ensures that each assembly is ready on time, complete and correct. Employees assemble the components into a kit either in the warehouse during picking or at a separate workstation.

The process can run via the ERP or directly via the warehouse management system:‍

• The ERP sends an order to create a kit.
• The warehouse management system automatically creates the appropriate picking list.
• The parts are either sent directly to the picking area or to an assembly station.
• In the end, you have a complete kit as ordered.

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Challenge 6: Coordination of different storage types

Raw materials here, semi-finished goods there, spare parts there and finished products somewhere else. In between pallets, boxes, shelves, buffer zones and cold rooms. Companies also store materials, equipment and products in different sizes, quantities and states of aggregation. They use different types of storage for this: High-bay racking for pallets, shelving for small parts, cold storage for sensitive goods, long goods storage for bulky goods or buffer storage for materials without a fixed location.

There are also seasonal warehouses, decentralized locations and special warehouses for hazardous goods. Transportation between these warehouses requires special handling and precise coordination.

What happens if companies do not coordinate these warehouses?‍

• Stocks are lost.
• Supplies arrive too late.
• Production is at a standstill.
• And in the worst case: the customer waits in vain.

Smart solution: multi-storage capability

Our software connects all warehouses. Whether AutoStore, block storage, cold storage or hazardous goods storage - the system controls them centrally and synchronizes the processes. This allows you to maintain an overview. Data remains consistent and processes run smoothly. Whether fixed bin-oriented, chaotic, automated or manual - the warehouse works in sync.

With the multiple storage capability:‍

• View stocks per warehouse in real time.
• Control material flows directly.
• Trigger replenishment automatically.
• Coordinate consolidations efficiently between warehouses.

Bearing types:‍

• AutoStore
• Open space storage
• High-bay warehouse
• Block storage
• Shelf storage
• Pallet warehouse
• Cassette storage / long goods storage
• Small parts warehouse
• Cold storage
• Hazardous goods warehouse
• Cross-docking warehouse
• Seasonal camp
• Spare parts warehouse
• Buffer store
• Central warehouse or decentralized warehouse

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More about automatic bin location search: Say goodbye to tedious bin location searches, the software will do it for you.

If you need support from robotics, driverless transport systems (AGVs) or tugger trains could be a solution. Find out more:

1. Full speed ahead: How tugger trains get the internal material flow moving.
2. Automated guided vehicles: These nimble little powerhouses take over the transportation of goods.

Another interesting blog article for manufacturing companies: Logistics tips for optimization-minded companies caught in the treadmill.‍

The future of production is digital. It is networked and forward-looking. Our SuPCIS-L8 warehouse management software keeps production on the move. It supports reliable deliveries - even in turbulent times. New requirements? New products? New warehouse structures? SuPCIS-L8 grows with you, not the other way around. This keeps quality high. Because one thing is clear: if the warehouse doesn't run, production doesn't run either.