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How do you ensure error-free management of 6,000 different references from the automotive industry?

Centres AutoEquip are now able to manage a multitude of different car parts, and provide any single one within minutes, thanks to Mecalux’s Warehouse Management Software EasyWMS.

How do you ensure error-free management of 6,000 different references from the automotive industry?

Video transcription

Ignasi Mallol (Head of the software Technical office Mecalux)
Success always begins with good ideas, good management and plenty of hard work.
However, the key to solid growth depends on our ability to manage success.
That is why Autoequip entrusts its logistics operations to Mecalux's Easy WMS software.

CENTRES AUTOEQUIP is a company devoted to providing quick vehicle care and maintenance services, and is a specialist in tyre distribution.
You have to multiply the five basic tyres on a standard vehicle by all the possible brands, models, sizes, functions... Van or estate car? Land rover or taxi? Sports car or lorry? Mountain or city? Snow or sun? And so on...
That is why Autoequip manages a database with 6,000 different articles and more than 1,700 tyres in day-to-day use.

Javier Niño (Director of finance and operations Centres AutoEquip)
Autoequip began in a village very near here, Premià de Mar, with great hope and an obsession: to sell tyres at the most competitive prices and to provide the quickest service.
Today, we are leaders in Catalonia. Autoequip has 16 centres and operates two important new business lines: national distribution by Internet and international distribution—trading.

In 2009, in order to absorb demand and improve service, Centres Autoequip opened a new logistics distribution warehouse. The new facility has a total of 3,100 square meters, of which 2,700 are devoted to warehouse space.

Ignasi Mallol (Head of the software Technical office Mecalux)
The challenge was to find a system that would ensure optimum logistical management of the warehouse, integrating it into all the processes managed by the company's ERP.

Centres Autoequip set itself an objective: to automate warehouse processes in order to increase efficiency and achieve three goals:
- Ensuring that all orders are prepared as quickly as possible
- Capacity to manage a high and variable number of article types (more than 6,000)
- Optimisation of space and storage.

Ignasi Mallol (Head of the software Technical office Mecalux)
Thanks to its multiple functionalities, ease of communications between systems and simplicity in performing complex processes, our Easy WMS software was the option selected.

Javier Niño (Director of finance and operations Centres AutoEquip)
Because a customer can call me and say: I need just one wheel, and in five minutes I know where the wheel is, I go and get it and have it ready. Only Mecalux can give you that.

The warehouse was divided into seven different areas, and the system needed to manage these according to the processes defined at the study stage: conventional storage areas for containers and large cages; peak area with tyre picking shelves; floor area for cross-docking management; large amount of stock and quick reception buffers; car audio product storage area; and dock area.
The site is fitted with conventional shelves, tyre picking shelves and floor areas, with a total of 8 storage aisles, 2 reception docks and 5 dispatch docks.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
We have 7 forklift trucks that we use to move around 3,000 wheels a day.

Easy WMS operates on 8 radio-frequency terminals with a single workstation in the warehouse.
Once the study, configuration, launch and training stages had finished, an inventory was completed and the warehouse opened, performing the following operations:

Juan Carlos Astasio (Integral logistics manager Centres AutoEquip)
Operators unload the lorry and, as the unloading process continues, one calls out the following information: reference, number of units and the container we are going to put the goods into. Once a container is full, we make a report from our ERP system to the Mecalux SGA system. The operators then take the Radio Frequency Terminal (TRF) and read the type of container. Once this has been read, they are known told where to place it.

The system performs cross-docking if there are lines of orders pending.

Juan Carlos Astasio (Integral logistics manager Centres AutoEquip)
If not many units enter, what we do is, we consolidate it in another type of container and the TRF tells us where we should put the tyres,

They will be placed in the peak or full container zone through an article replacement or consolidation process, when these containers are filled up again with the same product. In this way, Mecalux's Easy WMS optimises container capacity and, in this way, warehouse space.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
It tells us exactly where to place and where to pick each type of tyre on all customer orders.

- The ERP sends orders automatically.
- The warehouse manager assigns orders to operators according to their workload and capacity.
- Waves of orders are generated so that orders can be prepared in blocks, optimising the route.
- The operator's route is optimised, beginning with the orange zone on, to create a natural route to the dispatch docks.
- The warehouse is divided into zones according to the down-up rotation of articles in order to minimise goods movements and ensure that operators have direct access to goods.
- Once the order has been served at the dispatch dock, the dispatch is automatically closed and confirmation of the prepared and dispatched order is sent to the ERP.
Easy WMS also allows other processes to be performed:
- Permanent inventory.
- Automatic product rotation calculation
- Generation of container and location labels
- Generation of customised reports and statistics

Ignasi Mallol (Head of the software Technical office Mecalux)
But results are the important thing. Let's see how Autoequip has benefited from Mecalux Easy software.

Javier Niño (Director of finance and operations Centres AutoEquip)
We have increased our capacity by 100 per cent, from 15,000 to 30,000 wheels.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
At first, we were handling a couple of lorries a week, more or less. Now, it's one or two a day.

Juan Carlos Astasio (Integral logistics manager Centres AutoEquip)
We have increased dispatches by 60 per cent, from 150 a day to 240.

Ignasi Mallol (Head of the software Technical office Mecalux)
Mecalux Easy has helped Autoequip to consolidate the company's success.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
The amount we have grown is... awesome.

Ignasi Mallol (Head of the software Technical office Mecalux)
The system has enormous potential, enabling us to increase the complexity of our warehouse management, opening up to the future.

Javier Niño (Director of finance and operations Centres AutoEquip)
We plan to increase the capacity of our warehouse here by approximately 70 per cent.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
In a year or less we will be moving double the number of tyres.

Javier Niño (Director of finance and operations Centres AutoEquip)
We could easily be talking in terms of 120 per cent growth in three years.


Pallet inspection: Size, weight and structure

This ensures that only pallets in optimum conditions get into the automated circuit. We can monitor the size, weight and condition of the pallet, to ensure that they are suitable.

Pallet inspection: Size, weight and structure


Move pallets from rollers to chains

A conveyor that combines both rollers and chains, making it possible to transfer pallets from one system to another, while making changes of direction through 90°.

Move pallets from rollers to chains


Pallet transfer between unaligned conveyors

The layout of transportation systems for pallets can vary greatly. This conveyor lets you cover angles of 45°, 60°, 90° and 180° in relation to the incoming direction.

Pallet transfer between unaligned conveyors


Lifting pallets to different heights

Join two or more levels and turn the problems associated with transporting palletised unit loads into a thing of the past. This lifting system can be easily incorporated into warehouses of type.

Lifting pallets to different heights


Stacking and re-distributing surplus pallets in a transportation circuit

Telescopic lifting forks are used either to stack empty pallets one on top of the other, or unstack them. Used in specific circuit layouts.

Stacking and re-distributing surplus pallets in a transportation circuit


Twin-mast cranes in single deep racks: Combined cycles

A combined cycle is the average time required to store and remove materials in a single movement.

Twin-mast cranes in single deep racks: Combined cycles


Stacker cranes: Extractions in double-deep racks

Automated retrieval systems that work in double-deep racks, such as stacker cranes, offer a great balance between storage capacity and handling speed. Relocation is required when working with the second unit load.

Stacker cranes: Extractions in double-deep racks


Combined cycles in double-deep racks: Relocations

Ratios of combined cycles when double-deep racking systems are somewhat lower. Discover the relocation concept and boost storage capacity

Combined cycles in double-deep racks: Relocations


Single-deep stacker crane: a single cycle

Automated warehouses with single-deep racks: Stacker cranes load or unload a single pallet on one side of the aisle and then return to their starting position.

Single-deep stacker crane: a single cycle


High performance in compact pallet racking

When combined with fast handling equipment, Pallet Shuttle systems offer high-speed workflows, making your warehouse fully automatic.

High performance in compact pallet racking


Step-by-step construction of a clad-rack warehouse

Discover how a clad-rack warehouse is built, step by step, from the assembly of the structure to the installation of the cranes and cladding. A feat of engineering that will leave you in awe.

Step-by-step construction of a clad-rack warehouse


Mecalux to centralise logistics at Nupik International

A new logistics centre installed in Polinyà has allowed Nupik International to centralise logistics operations, concentrating the activity of five warehouses into one fully-automated facility with an incredible capacity of 28,000 pallets.

Mecalux to centralise logistics at Nupik International

Video transcription

Nupik Internacional, a leading company in the manufacture of single-use tableware, has consolidated 5 of its warehouses in its headquarters in Polinyà, Barcelona.

A fully automated warehouse with an area of 8,000 m2, that can respond to the order peaks generated by seasonal demand.

The new automated warehouse designed by Mecalux is comprised of one building for storage, picking and shipment of orders.

Next to this there is a tall, Rack-clad warehouse enabling a total storage capacity of 28,000 pallets.

The processes of storage, reception and shipment are fully automated and optimised using the Easy WMS warehouse management software from Mecalux, enabling permanent inventory and full traceability of merchandise

Reception of merchandise to the store may be carried out automatically and manually.

A zone in the shipment area has been prepared for the manual reception of pallets from other production or handling centres.

A tunnel links the production lines to the warehouse through an automatic transport system that enables a continuous flow of pallets. This is a two-way system as it also allows goods to be carried to the production area.

A total of 6 lifts smoothly and effectively connect the different warehouse levels, the production warehouse and the shipping area.

Pallets are grouped on friction accumulation conveyors and automatically move to the identification and control point.

A scanner does the reading and the Easy Warehouse Management software selects their placement.

If necessary, the pallet is wrapped in order to prevent uncontrolled movement of the load.

The reception identification point measures, weighs and verifies the perfect status of each pallet.

Within the facility, pallets may have different destinations: the storage area, the picking area or directly to shipping.

The Nupik automated warehouse is serviced by double-bottom stacker cranes with Shuttle Car, using the most advanced technology.

In the double bottom storage area a total of 5 stacker cranes are installed that place pallets to be sent to the picking area with average turnover references.

Telescopik forks are able to place and pick up a load located at the second deep.

The entry and exit of material may be carried out in a single movement, enabling 229 combined cycles per hour.

The automated warehouse is also equipped with 3 stacker cranes with a shuttle car, enabling the storage of a large number of pallets by reference and also those that are issued complete. This storage system maximises available space.

The stacker cranes lift the merchandise while moving longitudinally at the same time, improving location and collection times.

The shuttle car moves the pallets from the entry point to the placement position that the Easy WMS management system has specified.

By using the shuttle car, the operating time of each manoeuvre is reduced and the LIFO system is applied, in which the last pallet in is the first out.

A corridor physically connects and integrates the different areas: production, picking platform and storage area.

In the picking preparation area automatic and manual orders are carried out and a total of 32 simultaneous orders is possible.

In the central area, the pallets that the robot handles accumulate according to the requirements of the subsequent orders.

The monitor indicates which layers must be released and the operator cuts the protective film.

Subsequently, the robot or the shuttle places the empty pallets on preparation points.

The anthropomorphic robot can prepare three orders simultaneously and is capable of handling up to 150 layers/hour or, in other words, more than 1,000 boxes/hour.

The Easy WMS management software optimises the stackability and sequencing of loads, thus increasing effectiveness, saving time and minimising costs.

Some orders are carried out semi-automatically, the robot begins its preparation and the shuttle moves the pallet to the operator in order for the operator to complete it.

Manual picking consists of 2 platforms with a total of 16 preparation posts that enable the handling of many different references quickly and easily.

This process is always guided by interactive visual indications.

The system is equipped with safety measures ensuring the protection and integrity of installation personnel.

The shuttles take the prepared orders and transfer them to the wrapping area.

Merchandise is wrapped at a rate of 70 pallets/hour.

Finally, the pallets are labelled and transferred to the shipping area using lifts.

Complete pallets that do not pass through the picking area are labelled in the shipping area.

All pallets arrive at this area and are then transported to a double shuttle, which places them into dynamic channels, enabling grouping and sequencing of the merchandise.

The Easy WMS management software groups the merchandise by route, vehicle, customer, delivery order or other characteristics.

This automated warehouse management system is a high-level technological solution, which enables Nupik to provide rapid service to its customers and to consolidate its international expansion.

 

A LEADER IN ACTIVE LOGISTICS


Mecalux completes the Porcelanosa Group´s logistics complex

With the addition of this automated warehouse to Porcelanosa’s logistics complex, Mecalux completes one of the most advanced logistics infrastructures in the ceramic industry.

Mecalux completes the Porcelanosa Group´s logistics complex

Video transcription

The heat of fire, the humbleness of sand… basic elements on which Porcelanosa has built a solid business group which covers all sectors of ceramics, from tiles to solutions for the most contemporary of architecture.

 

5 logistics centres in Castellón are the result of years of close collaboration with Mecalux, which has designed and implemented the best solutions for each project, providing “innovation, technology and excellence” in each one. Three words that sum up their working philosophy and turn them into the best allies of a large group like Porcelanosa.

 

Mecalux took its first steps in this great project with the Porcelanosa logistics centre in 2003, followed by the Ceranco centre. Six years later the l’Antic Colonial and Noken centres were built, and finally Venís in 2011.

 

Venís, a pioneering flooring company, with a wide variety of types and finishes, is the last of the 5 logistics centres built by Mecalux for the Porcelanosa Group. This centre is fitted out with the most recent technological developments present in each and every part of the circuit.

 

The cycle starts with the pallets with the finished product. These mostly come from the production centre, connected to the silo through an underground tunnel more than 1 kilometre long.

 

Monitored along their route by Mecalux’s Easy warehouse management software, they are lifted on the double lifts that allow two pallets of up to 1,600 kg each to be loaded until they reach the aisle entrances of the store.

 

In addition to the tunnel entrance, the store has another auxiliary entrance for pallets from other centres.

 

The pallets are moved on the roller and chain conveyors to the identification point, where Mecalux’s Easy warehouse management software controls any incident. Here each pallet is measured and weighed and it is made sure that they are in perfect condition.

 

The auxiliary entrance is also used for bringing in empty pallets. Both these and those from other centres comply with rigorous quality control.

 

 

Venís silo: 7,000 square metres, 31 metres high and with a capacity to store 65,000 pallets.

 

The silo structure comprises 10 aisles where 10 twin-mast stacker cranes circulate and lift the pallets to place them strategically following the orders of the Mecalux Easy warehouse management software.

 

The faster-rotating goods are placed closer to the aisle entrance.

 

The twin-mast stacker cranes operate at a speed of up to 180 metres per minute and are able to perform as many as 237 combined cycles.

 

The stacker cranes are capable of recovering an average value of 15% of the energy consumed for self-consumption.

 

This logistics centre project created by Mecalux especially in accordance with Venis’s needs, also has space for future extensions to be built.

 

Goods delivery has also required specific solutions from Mecalux, both for the more complex picking zone and for and that of full pallets.

 

Eight work posts have been set up in the picking zone, able to prepare a total of 31 orders at the same time.

 

Pneumatic arms allow operators to handle the load effortlessly, facilitating movements with weight and speeding up the whole process.

 

The tables are fitted with height-adjustable hydraulic systems for greater ergonomics for workers.

 

The Mecalux Easy warehouse management software controls the preparation and the dispatching, enabling 4 orders to be completed at a time at each picking post.

 

Two double shuttles run along the picking aisles, keeping the safety distance and distributing the loads on the output tables.

 

All details count in the Venís logistics centre. Mecalux built a tunnel in Venís to connect the picking zone with the dispatch area to avoid the shuttle circulation area.

 

The delivery zone has two areas for full pallets and another two for those coming from picking.

 

The full pallets are distributed along 6 lines on either side of the silo. Those coming from the picking zone are wrapped to be shipped.

 

The large variety of Porcelanosa products has generated specific requirements in some of the group’s logistics centres. This is the case of l’Antic Colonial, where the parquet flooring is stored in large, wrapped flat packs requiring double pallets for storage.

 

Mecalux has designed lifts, stacker cranes and picking posts especially for these unconventionally large items.

 

In the case of Noken, another of the companies of the Porcelanosa Group, which stores small products as a manufacturer of taps and bathroom units, Mecalux designed an automatic warehouse for boxes instead of pallets. A solution that provides greater agility in goods input and output.

 

This is the daily work of the logistics centres of the Porcelanosa Group, a company that has risen as a benchmark of quality and innovation at the service of logistics. A challenge taken on by Porcelanosa and Mecalux now more than 15 years ago materialised in the 5 automatic logistics centres built to date.

 

Mecalux and Porcelanosa. A long trajectory offering the best products to their customers. Mecalux technology and experience for the Porcelanosa Group.


Mecalux as a provider of global e-commerce solutions

The Easy WMS software allows Tradeinn to efficiently control its growing volume of data and stock.

Mecalux as a provider of global e-commerce solutions

Video transcription

Tradeinn is an internationally recognized e-commerce firm in the sale of sports equipment.

With its headquarters in Celrà, Girona, Tradeinn began doing business in 1997. Today it has 13 speciality online stores. Year after year, the company has been growing and developing, reaching some incredible numbers:

  • 13 Specialty online shops
  • More than 1,000,000 SKUs for sale
  • Sales in 220 countries
  • 1,000,000 customers
  • Averaging 2,000 orders per day

Since its inception Tradeinn has relied on Mecalux as a provider of global e-commerce solutions.

DAVID MARTIN (CEO at Tradeinn)
Mecalux has been an essential partner in our growth during the different stages that we have gone through these past 6 years, in which our sales have multiplied by 40. Because they have helped both in supplying racks for each warehouse we have been located in and also with the radio frequency software, Easy. The truth is that “Easy” has helped us enormously in managing the more than a million products that are in our catalogue and in reducing the costs of preparing a package, which is very important in the case of an e-commerce company.
 

The warehouse is 7,000 square meters in size, equipped with picking racks that are adjustable to any product size, from skis to wetsuits, and they are set up for future growth.

The management of the warehouse with the Easy WMS software allows Tradeinn to efficiently control its growing volume of data and stock.

Ramon Alvarez - CLO (Chief Logistics Officer)
Which meant the implementation of Mecalux Easy at Tradeinn was to "streamline", i.e. knowing at all times what we have, where we have it and how we have to prepare it. We now turn over the same amount of volume in a single month as we did in the whole of 2011. We realized that we had to integrate a warehouse management software at the time when we moved because traditional management was impossible.

 

Tradeinn’s objective is that when a user clicks the "Proceed to Checkout" button a process starts that is completed when they receive the correct product at their homes, on time.

The most important stages of this process are in the management of stock and the fulfilment of orders.

This involves different actions controlled by Easy WMS, such as:

  • Reception of material and new releases in the product master records…
  • Streamlining of the operator’s movements…
  • Inventory in real time…
  • And cross docking.

Ramon Alvarez - CLO (Chief Logistics Officer)
One of the developments made, which has been very successful, is the cross dock, which allows us to receive and dispatch material without it being put into the racks, minimising time, costs and operations.
 

Averaging 2,000 orders per day, the speed and accuracy in the preparation of orders is the most important process. Tradeinn defines its business as "a factory for preparing packages".

Ramon Alvarez - CLO (Chief Logistics Officer)
We can easily absorb the growth that the company is experiencing, as the software can withstand it, manage it and there is no problem. In terms of inputs, we are receiving 80% more than last year. In terms of outputs, we are shipping out 70% more than last year. The integration of stock in the last inventory was 99.98%. Easy has everything under control, all of these parameters, and helps us to be able to accomplish everything on time.
 

To be able to make large scale preparation of products, Tradeinn has reconfigured parcelling operations, distributing it onto tables. To further increase productivity, Easy WMS allows for working with orders in waves: they can currently launch 600 orders at the same time.

The features of EASY WMS also enable the management of point of sale stores, whether they have their own stock or not, as in the case of the store that Tradeinn has next to its logistics centre, which is treated as if it were another customer.

DAVID MARTIN (CEO at Tradeinn)
We chose Mecalux as a partner due to the reputation that the company has in the market. We started to work a bit at a time putting up parts of the racks, when we needed to install a software we examined several options and Easy was the one we liked the most. And as we already had good referrals and we had previously worked with Mecalux, we decided to go ahead with them.
 

By choosing this storage solution and the Mecalux Easy WMS management software, Tradeinn was provided with the flexibility, versatility and response capability necessary to adapt to the relentless innovation that the e-commerce sector experiences, becoming a business leader in continuous development and growth.


Mecalux delivers a turnkey installation to the highest producing Michelin tire plants in Europe

The solution by Mecalux has made the Michelin manufacturing centre in Vitoria a pioneer in its sector.

Mecalux delivers a turnkey installation to the highest producing Michelin tire plants in Europe

Video transcription

Michelin, 130 years manufacturing tires for any vehicle around the world.

One of the largest, highest producing Michelin tire plants in Europe is located in Vitoria, Spain. The facility’s elevated manufacturing flows required a fine-tuned logistics solution able to manage the business growth achieved in recent years, driven in part by the planned addition of a fourth production line.

 

The solution provided by Mecalux is designed with Michelin’s standard container dimensions and characteristics in mind. These metal containers flow through the entire installation and are set directly in the racks without needing a base pallet.

The automated clad-rack warehouse is 27 metres high and comprises 5 aisles where 5 single-mast stacker cranes operate. Divided into two floors, each level runs a different operation: inputs are carried out on the lower level, and outputs on the upper.
 

Double stacked containers arrive directly from the production plant. A full pallet stacker mounted at the entry point unstacks the containers and sets them on the chain conveyor, all pallet-free. Next, the conveyors shift the containers to the storage aisles; a stacker crane then collects and inserts them in their assigned location.

Inside the automated warehouse, the goods are stored as per the commands of the Easy WMS warehouse management system, designed by Mecalux. The Easy software has been adapted to the BSM communications system of Michelin, meaning output management is fully customised. Easy WMS controls product tracking through virtual instructions, and always knows where to find each and every container and if that container has exited or not..

The racks are specially designed to direct-store containers, thanks to cross-ties that support the container legs in a completely secure manner.

Outputs flow through the upper floor, serviced by a double transfer car that carries the containers to the dispatch zone. This transfer car can hold two containers at a time, making it possible to sequence the load and streamline workflows.

In this zone, 4 full pallet stackers restack the containers, to reduce loading times and optimise the space inside the transport vehicles.

Antonio J. García-Montalvo / Project Manager ASRS Z/VIT / Technical office / Michelin
This warehouse has a 4600 container capacity, which will accommodate the containers generated by 3 already up and running production lines, as well as a fourth prospective line, and it also has a capacity for 120 containers an hour. It was crucial to be able to retrieve containers off the lines and also supply containers to the delivery vehicle docks. Presently, everything is running very smoothly.
 

Mecalux also set up a fire safety system, enclosures and a cooling system that keeps the temperature between 10 and 27 degrees.

Mecalux has delivered a turnkey installation to Michelin that operates 24 hours a day, 7 days a week.

The solution by Mecalux has made the Michelin manufacturing centre in Vitoria a pioneer in its sector. Innovation and technology at your service.


Goods dispatch: The last step before leaving the warehouse

Through the use of outbound gravity-flow lanes and Warehouse Management Software, goods can be gathered in the dispatch areas, sorted by route, vehicle, customer, etc.

Goods dispatch: The last step before leaving the warehouse

Video transcription

Goods are taken to the dispatching área

If necessary, pallets are labelled

Pallets are carried to a shuttle, which is doublé in this case.

The system can carry pallets of different weights.

Easy WMS management software groups goods by route, vehicle, client or other criteria.

Dynamic shelves allow grouping and sequencing goods without using electricity.

Brake rollers keep the moving speedconstant and maintain stability.


Automated miniload warehouse

The automated miniload warehouse is an automated storage system for boxes or trays

Automated miniload warehouse

Video transcription

Automated miniload warehouse

The automated miniload warehouse is an automated storage system for boxes or trays, an all-in-one installation with racks, a stacker crane, conveyors and the Easy WMS warehouse management system. It comprises one or more aisles with racks on both sides, where a stacker crane locates and extracts loads from the racks.

The picking area is located on the ends or sides of the racks. It includes conveyors where the stacker cranes deposit the loads extracted from the racks.

Once picking operations are completed, the box or tray is returned to its location.

The entire system is controlled by the Easy WMS warehouse management system, which maintains a permanent inventory in real-time.

Easy WMS. Real-time inventory

The automated miniload warehouse is ideal for companies carrying out high-paced picking.

Accelerated Picking. Miniload Solution

Optimal space usage

The automated warehouse for boxes can multiply the storage capacity of a pallet rack warehouse by 10.

The system allows optimum use of space due to it high-density storage, both lengthwise and in height.

Streamlined Picking

The stacker crane is tasked with moving the product needed to prepare orders to the picking stations. So, the operator can stay in the same place. This is a “product-to-person” system, which speeds up order prep.

High productivity

Automated warehouses for boxes provide high efficiency in input and output processes with the goods.

Cost savings - Fast return on investment

All of this contributes to cost savings and a rapid ROI.

Safety first

Workflows are done safely and easily, protecting both the load and personnel.

The miniload warehouse solution provides speed and safety. This system is suited to companies from any sector, especially those performing accelerated picking.

Advantages

  • High performance.
  • Save space, time and costs.
  • Real-time inventory.
  • Maximum ergonomics & safety.
  • Accelerated Picking.

Construction of the tallest cold-storage warehouse in Europe - Timelapse

The tallest cold-storage warehouse in Europe


The new Grégoire-Besson distribution centre guarantees fast, accurate order preparation

The combination of three storage systems lets merchandise be organised according to their characteristics and demand, streamlining order picking tremendously.

The new Grégoire-Besson distribution centre guarantees fast, accurate order preparation

Video transcription

In the Grégoire Besson logistics centre, a French multinational specialised in manufacturing farm equipment, everything is organised by a criterion of maximum throughput and increased productivity.

Gabin Guegan - SPARE PARTS MANAGER
This project had to fix a problem area, centralising spare parts dispatches from the six different manufacturing plants of the Grégoire Besson group. And, we also wanted to step-up outputs, which is the bottom-line for selling our equipment. So, we checked out different suppliers to try to get past both logistics, and IT issues. And, soon it was clear that Mecalux, with it solid grip on project management, was the way to go.

 

The outcome is a highly organised, 4,500 m2 warehouse with very streamlined order picking.

Gabin Guegan - SPARE PARTS MANAGER
A potential business partner would need to deliver a comprehensive technical solution that could take on everything from storing small parts, like a single bolt, up to 5 m high boxes. So, we chose a triple storage solution: pallet racks for heavy and large-sized parts set on Europallets; the miniload warehouse for storing high rotation spare parts, which represents 70% of our products; and, lastly, cantilever racks to store bulky products.
 

The storage zone features versatile pallet racks that adapt to a wide variety of SKUs of distinct rotations, sizes and volumes. These racks store both palletised goods and containers.

Upper levels hold reserve products. Meanwhile, locations on the bottom have pallets to pick off. Some of these racks include slide-out platforms to deposit containers on, facilitating picking for operators.

These 7.6 m high racks have a capacity to locate more than 4,400 pallets.

The miniload warehouse is composed of two aisles with double-deep racking on both sides that measure 47 m long, 9 m high and have 17 levels that house more than 10,000 boxes.

A stacker crane runs in each aisle, inserting and extracting goods from the locations automatically, according to the instructions of the Galileo control system. These machines work at speeds of 180 metres a minute and include an extraction system with telescopic forks that reach into second pallet positions.

The frontal warehouse area includes a roller conveyor circuit that shifts goods to the two picking stations, where waves of four orders are prepared at once.

Gabin Guegan - SPARE PARTS MANAGER
These days, our order prep is done in one fluid motion. That said, we still wanted to anticipate business growth at the Grégoire Besson group and deal with seasonal peaks in manufacturing. We can now accept orders an hour or more later than we use to with the miniload warehouse, meaning our throughput in higher since order picking takes less time.
 

The area with cantilever racking rounds out the solutions set up by Mecalux to offload over-sized products. These stand 5 m high and consist of columns and cantilever arms to rest the loads on.

A consolidation zone on the side of the warehouse is where orders are sent to be verified, then packaged and labelled.

The automatic management of the goods is done through the Easy WMS warehouse management system.

Gabin Guegan - SPARE PARTS MANAGER
Using the Easy WMS software, we have improved the quality of our in-warehouse logistics flows, both in receptions and dispatches. Our operators work autonomously, thanks to the task-by-task guidance of the system, from picking items up to loading the lorries. When we sat down with Mecalux to do a functional analysis, we planned out a certain number of functionalities suited to Grégoire Besson, like automatic printing of packing lists or management of supplier batch codes. This collaboration didn’t end there. We are still developing functionalities together to facilitate the day-to-day work of our personnel.
 

In front of the pallet racks is a reception and dispatch zone, where orders are closed before being loaded onto the lorries.

The multinational Grégoire Besson needed a long-term business partner to face its recent growth. Mecalux has answered the call by implementing effective, adaptable solutions, which means the company has topped out productivity thanks to efficient picking, a high storage capacity and a custom-fit warehouse management system.