%402x.svg){kind=icon}
How Zander Freiburg creates space and perspectives with an automatic mobile shelf.
The Freiburg branch of electrical wholesaler J.W. Zander GmbH & Co. KG stands on a site that has grown like a good forest: piece by piece, hall by hall. But at some point it became clear that there was no more space to be gained by conventional means. What to do when the throughput of goods grows, the number of articles increases and at the same time there is little free space? The answer: think in terms of movement. More precisely, in an automated mobile racking system, controlled by the warehouse management system (WMS) from S&P | Element Logic. However, the story doesn't begin with this project, but over ten years ago - with a decision that made both companies long-term partners.
From ERP to WMS
At that time, Zander Freiburg was still managing its logistics processes with the ERP system, which was increasingly losing flexibility and efficiency. It could no longer meet the requirements of a growing logistics landscape at the sites in Bochum and Freiburg. Those responsible therefore joined forces with the Fraunhofer Institute to search for a WMS. The choice fell on the software manufacturer S&P | Element Logic from Leinfelden-Echterdingen. The decisive factors were the strong standard functionalities, the low interface complexity, the high level of transparency and the technical expertise. The go-live took place in Bochum in 2014, followed by Freiburg in 2015. The processes are digitalized, paperless throughout and optimized with MDE devices and sophisticated picking strategies.
Space miracle with a system
However, growth, delivery capability and stockpiling strategies took their toll in 2023. Space became a scarce resource. So Zander Freiburg opted for an automated mobile racking system from Berger. A high-density storage solution with space for 2,600 Euro pallets on 1,200 square meters.
"For us, mobile racking was the only sensible solution to store pallet replenishment efficiently and in a space-saving manner," says Kerstin Falter, Logistics Manager in Freiburg. The racks stand on guide rails and move apart as required to provide access to an aisle. The technology is impressive, but also sensitive. "We move up to 100 tons per aisle. The whole thing can't just be moved quickly, it takes around a minute to open an aisle - making it ideal for replenishment," emphasizes Falter.
Store tightly, think wisely
The real intelligence is in the background: in the SuPCIS-L8 WMS. It not only controls the aisle opening, but also checks the load limits. The WMS calculates exactly which pallet can go where - depending on weight, height (there are three height classes), utilization and access logic. Each storage location knows its maximum load capacity, each pallet its weight.
"A 900-kilo pallet is not even suggested for the mobile racking, the limit is 750 kilograms per space," reports Falter. The load distribution in the rack is crucial, because tilting is not an option. "If the rack is loaded too one-sided, it can paralyze the system. The motor sits on one side, so the weight distribution must be right. Only then can the integrated rollers move cleanly and safely," emphasizes Falter.
The aisles are also not opened at random, but according to prioritization strategies. Is there a suitable space in the aisle that is already open? Can a double cycle of storage and retrieval be combined? Can another storage project be linked to this, such as the storage of several pallets in the same aisle? A new aisle is only opened if all queries are negative - this saves time and increases efficiency.
Automationmeets suitability for everyday use
The mobile racking is still operated manually. Employees with forklift trucks bring the pallets from the incoming goods area to the pre-zone. The rack opens according to the stored logic and the pallet is stored. If a replenishment is requested, the process also runs in two stages. The pallet is brought to the pre-zone and then moved to the pallet reserve or to the picking area.
But the future has already been considered: "We have designed the process in such a way that autonomous forklifts can be integrated. At the moment, the right framework conditions such as space and safety zones are still missing. But the course has been set," emphasizes Falter.
Transparency down to the last cable
The mobile racking system is not an isolated project, but is embedded in a well thought-out and logistical overall system. Particularly exciting: the cable drum management system including CPR number for proof of origin. Employees cut off the required length and the WMS calculates the remaining quantity in real time. To ensure that this happens efficiently, the WMS optimizes the routes. This is because unstructured routes would lead to delays. There are two areas: One aisle with smaller drums and one with large drums including the cutter.
"We know at all times where which cable drum is located, how much is still on it and when it needs to be replenished," explains Falter. "Each drum has a unique certificate number, which is continuously recorded in the WMS - from storage to delivery. In the event of damage, Zander Freiburg can trace exactly which batch is affected," explains Domenico Petta, Project Manager at S&P | Element Logic. Falter adds: "Without this number, storage is also not possible. If a cable is sold to a customer, the certified origin data automatically goes with it."
Not a silo, but a system
Incoming goods, picking, shipping and returns that go back into the warehouse - all of this is handled by the WMS. There are also smart connections such as a track & trace system, a shipping system for CEP service providers and digital parcel boxes. Customers can also collect their goods there outside of counter opening hours. Even special features such as special shipping notification processing for large orders are mapped in the WMS. The highlight: only the items actually delivered, for example 100, are transferred to the WMS. This saves employees having to search for the correct items.
"But not only that, the interface is also relieved. This is because no data record has to be reported back to the ERP, such as with 90 "zero messages" for undelivered items," emphasizes Petta.
Short delivery times
Every order that arrives by 9 p.m. is still being processed. Anything that arrives later is automatically transferred to the next day's run. What sounds like a simple service promise is actually based on configured time windows in the WMS. For example, a double delivery is planned for the tour within Freiburg: once early in the morning and once at midday. During order picking, the system automatically prioritizes the orders that are assigned to these time slots. "Adjusted parameters apply to more distant destinations," adds Falter. In addition to speed, this fine-tuned control also provides planning reliability for employees and customers.
Performance in the practical test
The results speak for themselves. The stored strategies and the automatic control of the mobile rack have noticeably streamlined the process. Zander Freiburg was able to reduce its picking times thanks to optimized routes, picking and packing processes and multi-order picking. The cross-docking process eliminates unnecessary storage and retrieval of goods that leave the warehouse straight away. Warehouse processes are visualized with the help of dashboards and stocktaking takes place continuously without disrupting warehouse operations. This eliminates the need for time-consuming key date counting for over 34,000 stock items.
"We can track what was done and when at any time. This not only helps us with complaints, but also makes us faster, more precise and more resilient overall. What used to be almost impossible to keep track of manually is now transparent and paperless," says Falter.
Zander Freiburg can also handle individual labeling, Kanban deliveries and the storage of custom parts, including a special inspection process for industrial customers.
10 years of trust
Of course, things sometimes grind to a halt or don't quite go according to plan - Falter is that honest. Especially after the takeover of S&P by Element Logic, the structure of the collaboration has changed. The new project organization is professional, but more complex and less flexible. This requires both sides to find new ways of finding pragmatic solutions.
"What counts, however, is that problems are taken seriously and solutions are found together. Malfunctions in the control center or minor errors are rectified promptly. And the personal level is right here," adds Falter.
What does the future hold? More automation, more digitalization and an even stronger focus on the customer experience. Because ultimately, customer satisfaction is also crucial in logistics. "At the same time, we are thinking about our employees. We have to design processes in such a way that career changers can work with them without errors. This also applies to linguistic and visual support in the WMS. In times of a shortage of skilled workers, ergonomics in the process becomes a strategic component," says Falter. Zander Freiburg shows how processes can not only be mapped with a WMS, but also intelligently thought through - right down to the last row of mobile shelves. The partnership with S&P | Element Logic proves that if you invest continuously, you can achieve great things even in the smallest of spaces.
Thanks to Kerstin Falter, Logistics Manager at Zander Freiburg, for the interview.
