Multishuttle lifts productivity 50% for Bosch Rexroth

“Growth and rising customer requirements meant our DC had hit its limits,” said Joachim Roß, Head of the Bosch Rexroth DC in Laatzen near Hannover, Germany. “We needed a future-oriented solution that would enable us to increase order picking and goods flow within the warehouse.”

“Dematic’s innovative use of a Multishuttle as a high-speed buffer relieves the load on our existing picking routes, improves access to stock and makes the best use of space all at the same time,” he said.

Bosch Rexroth Laatzen DC
The Laatzen DC covers an area of around 8,500 square metres. A high bay racking system houses 3,000 pallets, and a small parts automated storage and retrieval system (ASRS) provides space for 50,000 container locations. About 30,000 pneumatic products comprising around one million individual items are consolidated at the DC for global distribution.

Dematic Multishuttle meets need for speed
The DC’s existing small parts ASRS, conveyors and picking stations had a peak output of around 500 items/hr. To meet future targets, the DC needed to achieve a pick rate of 750 items/hr.

Supply to the 12 picking stations was the bottleneck. Dematic’s solution introduced a buffer store prior to the system’s sequencers, which ensures stock arrives at the picking stations in the correct order for assembly. Integrating the buffer store between the ASRS and the picking stations has reduced traffic on the conveyor system and the ASRS goods inward and outward processes.

It significantly improves the handling of containers that will be required multiple times in the compilation of a batch, especially fast-turnaround items. Thanks to the new buffer store, containers don’t have to return to the small parts ASRS every time they are used, but can remain within the buffer. The same applies to frequently requested items, and pre-picked order containers.

The disconnection and duplication of inward, outward and transport processes provides high performance levels as well as increased order picking and inward storage performance.

Because it is only for temporary storage, the high-speed Multishuttle buffer didn’t need to be particularly large, enabling the project to be completed without any extensions to the building. Multishuttle’s improved energy efficiency in comparison to conventional ASRS and, and its low maintenance requirements also minimise operating costs.

Making the best use of space
Unlike most conventional ASRS, Multishuttle systems do not need to be fitted directly onto the DC floor. The modular system design enables Multishuttle to be adapted to fit into the space that is available in existing buildings.

In Laatzen, a second level was integrated in the DC on a 3.50 metre high platform over the picking stations. The compact Multishuttle system with two 40 metre long aisles, five levels per aisle and a total of ten shuttles was installed above this.

The system provides space for 1,200 containers and achieves 1,000 double movements/hr. At this rate, the buffer turns over every hour or so.

“An intelligent and space-saving solution that not only meets the required throughput, but with its scalable expansion options also accommodates further growth,” said Mr Roß.

Exceeding expectations right from the start
“Right from the start the system not only met, but exceeded the expectations placed on it,” he said.

“With Multishuttle eliminating the supply bottleneck to the picking stations, the required performance of 750 container movements per hour is not a problem, and we can even process up to 900 per hour.

“It was a professional and optimal project implementation process that was commissioned without negatively impacting our ability to deliver,” concluded Mr Roß.

“For a comparatively moderate investment, thanks to Multishuttle we have been able to implement a solution for Bosch Rexroth that delivers performance levels that simply would not have been possible a few years ago,” said Rainer Alester, Sales Manager, Industrial Projects, Dematic.