PROJECT

NAGEL MASCHINEN- & WERKZEUGFABRIK
AUTOMATED SMALL PARTS WAREHOUSE.

NAGEL Maschinen- und Werkzeugfabrik GmbH is the world leader in the field of honing and superfinishing technology. Its innovative solutions have given NAGEL customers a valuable technological edge for more than half a century. Nagel employs over 1,500 people at seven locations.

In addition to the automotive industry, many other sectors use NAGEL honing and superfinishing technology: from compressor and mechanical engineering to hydraulics and pneumatics to medical technology. Wherever there is a need to solve demanding tasks in precision machining economically and efficiently, NAGEL is the competent partner.

With the implementation of the Automatic Small Parts Warehouse Fb Compact Warehouse, the company was able to ensure that all 650,000 different parts can be stored, transported and picked with maximum performance.

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INITIAL SITUATION & PROEJCT AIM.

  • Warehouse with stepped roof construction.

  • Predominantly manual warehouse processes.

  • Existing logistics components such as 3 Kardex vertical lift modules.

  • Four different software applications.

  • Goals:
    • Efficiency increase of the material flow while reducing internal production costs.
    • Simplified overview and handling of material and material flow across all warehouse areas.
    • Merging the four different software applications.

PROJECT REQUIREMENTS & CUSTOMER EXPECTATIONS.

The basis for the project was the requirement to install an innovative and compact warehouse solution that can both expand capacity and integrate existing systems. In addition, the main requirement for a simplified and clear operation of the entire system and all solution areas arose during the development of the project. These include the incoming and the outgoing goods processes, production supply and the three Kardex vertical lift workstations. For the realization of this goal, the material flow software Fb Stash was connected in addition to the Fb Compact Warehouse. This now forms the interface between the ERP system and all workplace connections and ensures a uniform user interface for all operators.

Due to the structural conditions in the hall, the racking for the Fb Compact Warehouse was installed with different heights. Due to the different rack heights, the length of the hall can be used until the very end, despite the sloping roof. Another requirement was the realization and implementation during ongoing operations.

  • Performance data:
    • 700 containers/day (storage and retrieval).
  • Container loads:
    • 300 * 400 * 220 mm -> 30 kg incl. container.
    • 600 * 400 * 220 mm -> 60 kg incl. container | can also be divided into 300 * 200 * 220 mm each with 15 kg incl. container.

INTRALOGISTICS SOLUTION.

  • Integration of an Automated Small Parts Warehouse with Fb Compact Shuttles and 3,480 storage locations.
  • Integration of the material flow software Fb Stash to control and manage all warehouse areas, consisting of:
    • Fb Compact Warehouse – Automated Small Parts Warehouse (AS/RM).
    • Manual pallet warehouse.
    • 3 Kardex vertical lift modules.

CUSTOMER BENEFITS OF THE 360+ Fb COMPLETE SOLUTION. .

  • Increase in storage capacity, improved throughput and relief for employees.

  • Optimal connection of all storage areas as well as simplified and uniform operation and control. Customized goods-to-person picking.

  • Maximum use of space thanks to the two-level racking of the Fb Compact Warehouse with Fb Compact Shuttles. The different ceiling heights are fully taken into account in the intralogistics solution.

  • Automated storage processes for loads up to 120 kg.

  • Throughput: 50 double cycles/hour achieve optimum efficiency for the necessary requirements.

TECHNICAL DATA

Fb KOMPAKTLAGER – AUTOMATED SMALL PARTS WAREHOUSE

3,480 storage spaces.
24 * 11 * 5,4 m (L / W / H).

THROUGHPUT

50 double cycles/hour.
700 containers/day are stored and retrieved

CONTAINER

300 * 400 * 200 mm with up to 30 kg.
600 * 400 * 220 mm with up to 60 kg | can also be divided into in 2x 300 * 200 * 220 mm each with 15 kg.

SYSTEM AND WORKPLACE CONNECTIONS

Incoming goods station.
Order picking stations.
Outgoing goods station is directly connected to the Fb Compact Warehouse.
Kardex vertical lift modules.

Fb COMPACT SHUTTLE AS A TRANSPORT UNIT

2x Fb Compact Shuttles.
Max. payload: 120 kg.
Max. speed: 2 m/s.
Max. acceleration: 1 m/s2.
Quadruple depth storage.
Shelf-level independence for full automation beginning with the very first shuttle.
Flexibly expandable for higher performance and fail-safe operation.

VERTICAL CONVEYOR

One high-performance vertical conveyor for transport of the shuttle between levels.

WAREHOUSE MANAGEMENT SOFTWARE

In-house software system for warehouse management, material flow control and storage automation.
A single software for control of the following intralogistics elements:

  • Fb Compact Warehouse.
  • Palette warehouse (manual warehouse).
  • Static shelf warehouse (manual warehouse).
  • Lightweight construction hall (manual warehouse).
  • 3 Stk. 3 Kardex vertical lift modules (goods-to-person systems).

On the software level, Fb Stash is between the machine control (e.g., PLC), the Enterprise Resource Planning (ERP), Production Planning System or the customer’s in-house Warehouse Management System (WMS).

DAVID BUCK

Head of Logistics, NAGEL Maschinen- und Werkzeugfabrik GmbH

“The cooperation with Fb Industry Automation has allowed us to considerably increase our throughput. The initial situation was that the employees had to use up to four different programs. In the course of the project, we were able to merge all systems in Fb Stash and relieve our employees.”

FELIX NEUMANN

Sales Manager, Fb Industry Automation

Our mission statement at Fb Industry Automation is to make automation possible for everyone. In other words, no matter how big or small the company is and how big or small the challenges are, automation is now an extremely important factor. Whether in manufacturing, e-commerce or mail order.

FURTHER CASES.

Magna Steyr – Automated small parts warehouse

Find out more about the possibilities of an automatic small parts warehouse as a replacement for an outdated storage and retrieval system. The Fb Compact Warehouse at Magna in Graz ensures highest possible cost efficiency with 19.000 storage locations. Magna is the world’s leading brand-independent engineering and manufacturing partner for automobile manufacturers.

Find out more »