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0.01% Picking Error Rate

Kärcher & TGW Logistics

Industrial Logistics

TGW Logistics Brings Automation to Kärcher’s Spare Parts Fulfillment System

Obersontheim, Germany

Reaching Kärcher’s Fulfillment Milestones

Kärcher is one of the world’s leading providers of cleaning equipment. Their diverse product line includes pressure washers, vacuums, and appliances for residential and commercial applications. From their distribution center in Obersontheim, Germany, Kärcher ensures fast replacement of over 60,000 spare parts and accessories for customers around the globe. This adds up to approximately 2.8 million order lines a year.

Rapid growth, an increasing product range, and a demand to supply directly to end customers necessitated a new concept for their center in 2009. Kärcher turned to TGW Logistics to automate their warehouse logistics and optimize spare parts fulfillment.

Our Objectives

  • Reduce lead times to 30 minutes  
  • Synchronize different picking areas  
  • Increase storage capacity by 40%  
  • Reduce picking error rate from 10% to 0.01%

How TGW Logistics Made it Possible!

To cope with their huge shipment numbers, Kärcher needed to automate warehouse operations, focusing on a faster, more efficient material flow. This meant rethinking their storage, picking, packing, and shipping processes.

Upgrades to Goods Receipt and Storage

The implementation of TGW Logistics’ automatic mini-load warehouse system provided approximately 95,000 storage locations for totes. Eight 77-meter-long aisles are equipped with Mustang storage retrieval machines. This automated warehouse logistics system supplies picking workstations with the required products.

Seamless Order Picking

The smart picking system consists of eight goods-to-person PickCenter workstations. Picking at these ergonomic workstations is done using two alternating source containers. Larger goods are picked in a separate area parallel to the small parts station. An energy efficient shuttle system works as an intermediate buffer to enable order consolidation–cutting shipping costs by reducing the number of packages sent to customers. The automated workstations promote higher order throughput by reducing the amount of walking required by employees. The system also allows for shorter processing times and supports order fulfillment via different channels (dealers, private customers, service installers, and shipment to international warehouses). Finally, the synchronized picking areas increase warehouse capacity, reduce transport costs through order consolidation, and reduce picking errors.

Coordinated Packing and Shipping

The shuttle system delivers small goods in totes to packing workstations. Larger goods are delivered manually. Packing takes place in the afternoon between 12:00-6:00 p.m., so orders are ready for shipment before departure time.

Strengthen Your Warehouse Logistics With Automation

TGW Logistics thinks outside the box to solve supply chain issues and help companies reach short- and long-term goals. Let us turn your vision into a reality.

Want to learn how TGW Logistics can help you optimize your logistics operations?

Contact us today

Erich Schlenkrich, Vice President Business Development Industrial & Consumer Goods | TGW Logistics Erich Schlenkrich, Vice President Business Development Industrial & Consumer Goods | TGW Logistics

Erich Schlenkrich

Vice President Business Development Industrial & Consumer Goods

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TGW Logistics è un'azienda di proprietà di una fondazione con sede in Austria e leader globale nell'automazione e nella logistica di magazzino. In qualità di system integrator di fiducia con oltre 50 anni di esperienza, offriamo servizi completi: progettazione, implementazione e manutenzione di centri di distribuzione avanzati comprensivi di meccatronica, robotica e soluzioni software innovative. Con oltre 4.500 dipendenti in Europa, Asia e Nord America, uniamo competenza, innovazione e un forte orientamento al cliente per supportare la sua crescita. Con TGW Logistics, trasformare la logistica del tuo magazzino in un vantaggio competitivo è possibile.

 

 

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