From the baking process of mellow pastries to the cutting-edge manufacturing of precision electronics, from the production of new energy vehicles to environmentally friendly water treatment technology, from the automation of small parts assembly to large valve drives...
In recent years, the Festo Group has built an intelligent manufacturing base and an automated logistics system in China, striving to provide more reliable delivery services and more competitive products to customers in China and the Asia-Pacific region. For the construction of Festo's Asia-Pacific logistics center project, Festo chose Swisslog's integrated warehouse automation solution, with the AutoStore system as the core, to achieve high-density storage and highly automated picking of 158,000 totes in just about 3,300 square meters. Now, the AutoStore system has been officially launched in September 2021 at the Festo Asia-Pacific Logistics Center in Shanghai Jinqiao Comprehensive Bonded Zone.
Small parts, footprints all over the world
Founded in 1925, the Festo Group focuses on the field of industrial automation and offers around 30,000 products, customised components and other related services to more than 300,000 customers in more than 35 industries worldwide, including pneumatic and electric cylinders, valves, servo controllers, valve terminals, fittings, sensors, connection technology, handling and assembly technology.
Thanks to the high quality and practical functionality of its products, Festo is trusted by customers in many industry segments. In addition, Festo is constantly improving its supply chain system to meet the value demands and experiences of customers around the world in terms of delivery, cost and service.
Festo Asia Pacific Logistics Centre: Order picking workstations
In April 2021, Festo fully opened its global production center in Jinan, Shandong Province, China. At the same time, Festo established an Asia-Pacific logistics centre in Shanghai, China, which was put into operation in September 2021 as an important hub for the global supply chain. "Festo's Asia-Pacific logistics center is an important part of Festo's global production and logistics layout, allowing products produced around the world to be delivered quickly to customers in the Asia-Pacific region, and products produced in China to other markets in the Asia-Pacific region and Europe and the United States. ”
In a modern warehouse, storage and picking are two important functions, and storage and picking equipment are often prioritized and determined. At the beginning of the design of the logistics center, Festo fully considered the characteristics of a wide range of stored product SKUs, large storage capacity and high throughput, and combined with the packaging of large and small orders and the delivery needs at home and abroad, it planned to introduce a fully automated, high-storage density and high-picking efficiency facility system. After several comparisons, Festo China decided to use the AutoStore system integrated by Swisslog to achieve efficient space use and fast order fulfillment in the logistics center.
Smart order fulfillment, giving a new definition to time and space
The warehousing function of Festo Asia Pacific Logistics Center is divided into two floors: the first floor is set up as a receiving area and a delivery area; On the second floor, there is an AutoStore system facility, equipped with 59 robot trolleys, 16 sets of high-speed rotary workstations, 158,000 storage bins, box conveyor lines, pallet conveyors and pallet lifting systems (responsible for transfer between floors). The AutoStore facility area on the second floor is a storage and picking function area covering an area of approximately 3,300 square meters.
The five components of AutoStore – bins, totes, mobile robots, picking stations, and control systems and management software – all play an important role in automating intensive storage and efficient picking.
01. Intensive storage and modular construction
Because the AutoStore storage area adopts a grid structure of cargo compartments, the bins only need to be stacked up and down in the vertical direction of the corresponding cargo grid, and then the mobile robot telescopic lifting belt grabs the bins in the corresponding cargo compartments, without the need to reserve and set up the roadway, thus saving space. In a space of only about 3,300 square meters and a height of only 7.5 meters, 158,000 standard storage bins are stored. Compared with the traditional storage method, the storage area is reduced by 70% under the same storage capacity, and the space is truly used efficiently.
Modular design, easy to build and expand, the system installation is like building a Lego toy, only a simple buckle and screw fixing of the standard structure is required to ensure the accuracy and stability of the overall structure, and the implementation process is accurate and efficient.
02. Efficient picking and precise collaboration
AutoStore achieves a very high density of storage without the need for aisles, so how does picking work? The answer lies in the robot that moves in four directions above the cargo compartment.
In principle, storage bins for relatively low-momentum SKUs will be placed lower in the tray, while storage bins for relatively high-momentum SKUs will be placed higher in the bin to achieve higher picking efficiency. After the order is placed, the AutoStore control system will assign tasks to mobile robots and picking stations, and multiple mobile robots can automatically assign tasks to complete multiple order picking together. The robot can automatically reach the position of the cargo compartment where the bin is located, release the lifting belt to grab the bin, and then carry the bin to the picking station position, and then release the discharge bin to the goods-to-person picking platform position through the lifting belt for picking. The entire process of automatic robot picking of target totes is controlled by Swisslog SAP EWM and AutoStore Control System.
The robot operates at speeds of up to 3.1 m/s
The minimum distance between the two cars is only 10 mm
Workstation picking efficiency of up to 450 cases per hour
03. Customized SAP EWM intelligent fulfillment
As the first system integrator in the industry to offer a connection between AutoStore and SAP EWM, Swisslog has developed a customized SAP EWM warehouse management system for Festo Asia Pacific Logistics Center. The system seamlessly connects with the customer's upper management system to realize the efficient collaboration of equipment, personnel and tasks in warehouse management, and then realize fast order picking and order fulfillment.
The AutoStore system continues to create value for you
In the case of Festo, the AutoStore system solution from Swisslog is highly standardized and modular, and offers many advantages: the AutoStore system is flexible for different heights, short construction periods, easy replacement and maintenance of components, low energy consumption for system operation, and easy expansion and upgrading of the system. In addition, when there is a car that needs to be repaired, only the car body needs to be treated separately, and the overall system operation is not affected.
Swisslog is an industry-leading provider of logistics automation technology that understands our business needs and provides customized support. We hope that Swisslog will continue to provide such high-quality services in the future, and the two sides will maintain a good partnership and jointly escort the logistics upgrade."
- Wang Su
Head of Logistics at Festo Greater China
Respond quickly to global order demands that require shorter procurement and customer service cycle times. Festo Asia Pacific Logistics Centre uses the AutoStore system to achieve intensive storage in a limited space, saving land and energy consumption. Automated picking reduces repetitive labor and labor costs, improves the working environment of employees, reduces human errors, and improves delivery reliability while shortening the waiting cycle for customers.
Swisslog's integrated AutoStore system solution will help more companies achieve higher delivery efficiency and a more competitive customer experience while maintaining high product quality, and continue to create value.
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