intralogistiknews - viastore systems

intralogistiknews - viastore systems

New warehouse for

Erbe Elektromedizin:

From Tübingen to operating

rooms all over the world

Page 4




viastore systems

intralogistik News

Volume 10

More space and better


System modernization

at orochemie

Page 8

Warehouse software

at a glance:

New viad@t brochure

out now

Page 12



SRM for efficient carton handling

Page 3

Automated warehouse for Erbe


Page 4

More space and higher throughput

at orochemie

Page 8

One WMS for various international

locations and different warehouse


Page 9

Info service

Page 11

New WMS brochure

Page 12

Cover picture

To ensure that the wide product range

of Erbe Elektromedizin arrives at the

operating table even more quickly and

smoothly and to further improve its

customer services, the company has

raised its logistic processes to the state

of the art level.

Page 4

2 intralogistik News 2|09

We can support you in all aspects

of warehouse safety

Dear Reader,

Roland Lachenmaier is

Head of After Sales at

viastore systems in


The safety requirements for machinery and equipment laid

down in the relevant EC directives apply to your intralogistic

system too. When, for example, the conveyor system or storage/retrieval

machines are technically upgraded or modified

it is often necessary to conduct a new risk assessment and in

some cases even to carry out complete CE conformity procedures

before putting the facility into operation once again.

When specialists such as viastore systems perform these

measures then they will also ensure compliance with all the

relevant standards. If, however, they are carried out in-house,

such risk assessments are often neglected due to lack of the

required resources and insufficient expertise. Quite often this

can pose a danger to life and limb of warehouse personnel.

To rule this out we offer you as a service a safety check of your

system and then, if necessary, carry out the procedures

required to obtain CE approval. This includes, for instance, the investigation

of relevant directives and standards, risk analysis, documentation in the

respective national language as well as issuing and attaching the CE mark.

We can also provide consultation when it comes to planning and buying new

intralogistic machinery, equipment and components so that we can turn

your attention to safety-relevant aspects early on.

Yours sincerely

Roland Lachenmaier

Back in 2004, viastore supplied a material flow system for the Cargill brand

Excel facility in Friona, Texas

Storage/retrieval machines for

efficient carton handling

viastore wins large-scale order for the food industry

viastore systems has won a large-scale order from Retrotech, Inc.

to be installed at U.S. food company Cargill Meat Solutions.

viastore will supply 15 viaspeed storage/retrieval machines (SRM)

for Cargill's expanded logistics center in Schuyler, Nebraska. The

load handling devices of the highly dynamic SRM can handle two

cartons at a time. In addition, viastore will supply the conveyor

and sortation systems. The logistics center has an expanded storage

capacity of about 50,000 cartons of beef. Meat processor and

distributor Cargill represents more than a dozen major U.S. brands

that are sold in both retail and foodservice channels. Fast and

reliable order processing is a must, especially in this business. The

facility in Schuyler is scheduled to go live at the end of 1Q 2010.

viastore is no stranger to Cargill. Back in 2004, it supplied a

material flow system for the logistics center of the Cargill brand

Excel in Friona, Texas.

Retrofit and warehouse


More storage space for

Eaux Minérales de St. Alban

Along with expanding its production

capacity, beverage supplier Eaux Minérales

de St. Alban has entrusted viastore systems

with the retrofit and enlargement of its automated

storage & retrieval system (AS/RS) built

in 2005. As a first step, the driverless transport

system will be replaced by a continuous

conveyor system in three stages. An

eighth aisle with a new viapal SRM will

be added to the system in the fall of

2009. In this context, the AS/SR conveyor

system will be adjusted and

extensions added to the existing

software applications viad@tWMS,

viad@tMFC and viad@tVISU. The

project is to be implemented

in close collaboration

between viastore

Germany and

viastore France.

St. Alban bottles

mineral water

from four local

sources and also

produces beverages

such as Pepsi,

Lipton and Seven Up

under license. The company

has a staff of 150 and

is one of three French subsidiaries of

the Dutch Refresco Holding.

intralogistik News 2|09 3


From Tübingen to operating rooms all over the world

Medium-sized Erbe Elektromedizin GmbH relies on automated warehouses

Whenever surgeons anywhere in the world use instruments for

high-frequency surgery or cryosurgery, vessel sealing or noncontact

hemostasis, then there is a good chance that these

instruments have been supplied by Erbe Elektromedizin GmbH.

With more than 550 employees and annual sales of more than

€90 million, this family-run company is represented in more

than 100 countries around the globe both through its own subsidiaries

and through the medical trade. Erbe's export rate

amounts to 80 percent. To ensure that the wide range of products

arrives at the operating table even more quickly and smoothly

than before and to achieve further service improvements, Erbe

has raised its logistic processes to the state of the art level.

viastore was entrusted with implementing the automated storage


Logistics as an additional core competence

Erbe was established in Tübingen (Baden-Württemberg, Germany)

back in 1847. Run by fifth generation family members, the

company today is a leading global supplier of high-frequency

and waterjet technology. The great number of patents registered

every year provides evidence of its successful and intensive R&D

activities. Another main focus at Erbe is on production which is

organized extremely efficiently according to KAIZEN principles.

However, the logistic processes used to take a back seat up until

recently. "We simply stored our materials and products wherever

there was free space," explains Michael Ankele, Head of Materials

4 intralogistik News 2|09

Management, Purchasing and Logistics at Erbe. But the requirements

were rising steadily. The company's increasing level of

internationalization meant that customers worldwide had to be

supplied quickly and reliably with the some 1,800 different sales

items. An efficient and future-proof warehousing solution was

called for. In this context, it also had to be taken into consideration

that decentralized warehouses were to be closed down,

at first in Germany and later on in the whole of Europe, in order

to avoid stock redundancies and achieve a higher level of transparency.

In addition, the Materials Management Department was

taking over more and more logistic tasks from production lately.

Certified system

In close collaboration with logistics specialist Martin Sayer,

Managing Director of the Stuttgart-based consulting and planning

company mips Consulting GmbH, Erbe developed a new

material flow and warehousing concept. A major element of this

concept is a new warehouse section. Altogether the reconstructed

existing facility, the new building and the new offices cover

about 54,000 sq.ft. (5,000 sq.m) and have 49,700 cubic yards

(38,000 cu.m) of storage capacity. The new section was built

directly next to the hall that was used as warehousing and goods

handling area. Today the goods receipt and the packaging of

manufactured goods are handled here. The new logistics center

and the new procedures comply with the stringent demands of

the U.S. Food and Drug Administration, who also issues direct-

ives for the correct handling of medical devices. This compliance

is crucially important for Erbe, since the U.S. market still holds

enormous growth potential.

Tray warehouse a central element

Central to the new logistic system is the three-aisle automated

mini-load system (MLS) with 4,854 tray locations. It accommo-

dates 60 percent of the finished goods and 1,800 replacement

parts as well as loan equipment, testing and measuring devices.

Larger products such as high-frequency or waterjet surgery devices

are placed directly onto the 23.6x47.2 in. (600x1,200 mm)

trays. For smaller items such as probes or vessel sealing instruments,

the trays are subdivided by means of standard plastic containers

and inserts. A conveyor loop in front of the MLS efficiently

supplies the three pick stations. These can also handle inbound

processes. Order picking is supported by laser beam technology.

In addition to the screen display, a laser beam indicates to the

pickers which container and location they should pick from.

viaspeed provides dynamics

The MLS is fitted with viaspeed storage/retrieval (S/R) machines.

These can handle up to 260 storage and retrieval processes an

hour. "viaspeed offers highly innovative technology and is

matched especially to the organization of mini-load and tray

warehouses," explains viastore's Project Manager Wolfgang

König. viastore as a general contractor also supplied the rack and

conveyor systems, the ESD protected pick stations as well as the

controllers and the viad@tMFC material flow system.

The MLS is complemented by several conventional, manually

operated storage areas, including a bulk location area and a

pallet section. They accommodate those products that are too

Central to the new logistic center of Erbe is the tray mini-load system supplied by


intralogistik News 2|09 5

6 intralogistik News 2|09

bulky for the automated system, and in the future they will also

be used for storing materials for production replenishment. "This

ensures high system reliability," explains Martin Sayer. Fast-moving

items are stored in a zone next to the packing zone. Moreover

there are special areas for hazardous materials and sterile goods.

Efficient inbound order handling

"We have extremely heterogeneous flows of goods into the

warehouse," says logistic specialist Martin Sayer. On one hand,

there are finished goods coming in from production. These are

packed outside the production area in front of the warehousing

zone and brought to the pick stations on trolleys. From here they

go to the MLS. The adjacent goods receipt area handles the

receipt of products manufactured for Erbe by other companies.

"These are about 25,000 items annually," says Michael Ankele.

Every day round about 50 trucks approach the site to deliver or

pick up goods. Every month 500 or so pallets are received and just

as many sent out. In addition, about 2,500 packages a month are

sent to customers.

The warehouse operators unpack the supplied goods and post

their receipt. At this stage it is already determined in which warehouse

zone the goods will be stored. Products destined for the

MLS are placed into containers with barcodes that are transported

to the pick stations. Here the containers are allocated to the

trays and transported to the storage location by the viaspeed

SRM according to the FIFO principle. Equipment in need of

repair, loan equipment given to customers to bridge repair times

and trade fair exhibits are also delivered to the goods receipt area.

From here they go to a special room for decontamination, are

transported to the service department and eventually stored in

the warehouse.

Efficient order picking

The pick operators in the MLS trigger the earmarked outbound

orders. The material flow system controls the transport of the

respective tray from the warehouse to the corresponding workstation

with the utmost efficiency. Here the screen display and a

laser mark on the goods indicate to the pick operator from which

transport unit to retrieve the items and how many. As a precautionary

measure, the operator first scans the pick container, then

the goods and finally the container in which the item is placed

for further transport to the pack station. Order consolidation of

the products from the different warehouse zones takes place

either in lanes in front of the packaging zone or – for smaller

shipments – in the throughput channels of a staging rack. "We

have three separate lanes for rush orders so that they can bypass

the normal orders," explains Martin Sayer. Following the

system-based check for order completeness, the respective ship-

The conveyor loop in front of the tray warehouse supplies the three pick stations.

ment is released for packaging and for shipment to subsidiaries,

partners and end customers all over the world. This makes over

92,000 delivery note items annually, not including internal


Fit for the future

"The new system enables us to respond flexibly to future

developments," Michael Ankele sums up. The central warehouse

generates synergies and enables high inventory security.

Moreover, the processes have become transparent and stable.

Now there's nothing in the way of continuing internationalization

– at least from the goods replenishment point of view.

Delighted with the successful project: mips Managing Director Martin Sayer, Erbe

Manager Michael Ankele and viastore Project Manager Wolfgang König (from left).

Picking is confirmed several times by scanning to ensure high process security.

A laser-generated cross indicates from which module the operator should pick

the goods.

intralogistik News 2|09 7


More space and

better performance

System modernization at orochemie

orochemie, based in Kornwestheim (Baden-Württemberg,

Germany), has entrusted viastore systems with the modernization

of its unit-load warehouse. A member of the Dürr-

Dental Group, the company specializes in the manufacture of

disinfecting and cleaning agents and has operated a threeaisle

automated storage/retrieval system (AS/RS) equipped

with a viapal SRM and a transfer car since 1997. Due to the

company's continuous growth and the enlargement of the

product range this warehouse was bursting at the seams so

that an enlargement became inevitable and the building was

extended by 105 ft. (32 m). In order to optimize the facility's

efficiency, the viastore modernization specialists analyzed the

warehouse processes. This revealed that it would be advantageous

to replace the transfer car by two more viapal storage/retrieval

machines. The control system of the existing

SRM and the material flow system will be brought to the

latest state of the art. Moreover, a couple of additional functions

will be added to the pallet conveyor system and the rack

system. The new conveyor elements will be integrated into the

upgraded S7 pallet conveyor system control. To ensure that the

SRM can operate without any problems both in the old and in

the new warehouse areas, the design of the racking system

will remain unchanged. However, the subdivision of the storage

locations was adjusted in order to allow storage of the ex-

8 intralogistik News 2|09

The warehouse modernization at orochemie has resulted in more space and

better performance.

tended product range accordingly. The existing viad@tWMS

warehouse management system will then be extended to cover

this new warehouse area too and the material flow computer

with the obsolete DOS operating system will be replaced by

up-to-date hard- and software. A high-performance computer

will map the entire material flow in the future. Due to

the extension and modernization of the warehouse sections,

orochemie will not only win space, but also achieve significant

improvements in overall system performance.

Forever Young?

If you are interested in learning how to make your warehouse

and logistics center fit for the future, we invite you

to order your rejuvenation package free of charge at

+49 711 9818-128 or

It contains everything you need to know about how you can

substantially increase the performance capacity of your


For even better service

Webcams in the SRM

In a number of facilities, viastore systems has installed camera

systems onboard the SRM for monitoring the storage and

retrieval processes. Equipped with fish-eye lenses that can flexibly

adapt to varying exposure conditions, these cameras offer a

good view of the load handling devices and the respective storage

location. Depending on the aisle length, the necessary access

points are installed either on the warehouse ceiling or at the front

side of the warehouse. In long aisles, they are equipped with additional

beam antennae. The cameras are attached to the hoist

carriage without complex cabling. They send their image data to

the central control station via WLAN connection. The control

station operator can view the filmed image sequences either via

viad@t for Viega USA

Software for various international locations and

different warehouse types

Viega, a system supplier for plumbing and heating equipment

headquartered at Attendorn (North-Rhine Westphalia, Germany),

and viastore systems have maintained close collaboration regarding

warehouse logistics for as long as since the 1990s.

Recently this collaboration advanced to an international level

when Viega introduced the viad@tWMS warehouse management

system at its three locations in the USA.

With its viad@tWMS software solution, viastore helps to ensure

high throughput and maximum transparency in the conventionally

operated Viega warehouses in Reno, Nevada and Merrimack,

New Hampshire as well as in the company's highly automated

facility in McPherson, Kansas. The multilingual features of

viad@tWMS make it possible that Germany-based Viega employees

can switch on to the American systems and find dialogs

in German – and this also functions vice versa with English and

other languages. Due to close collaboration between viastore and

McPherson, Kansas is one of three locations of Viega USA, where they not only

distribute but manufacture parts.

Viega's software development team, Viega employees will be able

to modify the viad@tWMS on their own, if required.

"Thanks to viad@tWMS we are now able to further expand our

excellent distribution network," says George E. Kilpatrick, Director

of Distribution at Viega USA. "Our distribution system is based on

high flexibility, an extremely low error rate and order processing

within 24 hours. The viastore software ensures that we can live

up to these principles."

Knowing what's up:

A camera attached to the SRM

helps to monitor storage and

retrieval processes.

the viad@tVISU system visualization or via a separate computer.

viastore systems can access the image data via the camera's IP

address and via the web browser. Thus the viastore service

department can support the customer wherever necessary. In the

event of system failure, a series of 20 images before and 20

images after the failure occurring are saved internally. This

enables instant analysis of the situation and mere hiccups can be

differentiated from real failure. Quick remedy is possible and the

number and duration of downtimes reduced.

intralogistik News 2|09 9


From September 28 to October

1, 2010, German exhibition

company Deutsche Messe

Hannover will be holding the

CeMAT RUSSIA trade fair in

Moscow for the first time. The

new fair will premiere at the

All-Russian Exhibition Center,

one of Moscow's top three exhibition

venues. Just like the

world's leading intralogistics

fair CeMAT (next to take place

in Hanover from May 2-6,

2011), CeMAT RUSSIA will span

on all aspects of intralogistics,

including materials handling and storage technology, packaging

and order picking solutions, material flow and ware-

Optotrap light curtain

Alternative for profile checks

Until 2000, the rotating beam light curtain "Optotrap" was a

widely used profile checking device for load carriers installed in

many intralogistic facilities. Manufacturer Sick stopped the production

of this component in 2004; repair options were still available

for a further five years which means that this support ends

this year. Now viastore has developed an alternative solution in

the form of a light grid. It can be installed quickly and costeffectively

either during major upgrades or as an individual

solution. The modernization can be implemented within a very

short time, including dismounting, installation and replacement

of contacts. The new light grid can be mounted into the existing

Optotrap steel frame; the PLC requires only minor adjustment.

10 intralogistik News 2|09

Come and join us:

Premiere for CeMAT RUSSIA

Deutsche Messe organizes new intralogistic fair in Moscow

Storage Transportation Logistics, Moscow, Oct. 26-30, 2009

Logistica, Utrecht, Netherlands, Nov. 10-14, 2009

CeMAT 2011, Hanover, May 2-6, 2011

housing systems, workshop equipment and transport systems

as well as warehouse management software, logistics services

and outsourcing.

CeMAT RUSSIA will be held concurrently with and at the same

venue as MDA RUSSIA, Surface RUSSIA and Industrial

Automation RUSSIA under the parent brand "Industrial Trade

Fair Moscow". This arrangement will allow the four industrial

tradeshows to feed into each other, generating excellent crossindustry

business opportunities. International exhibitors will

benefit from this latest international rollout of Deutsche

Messe's winning trade fair formula.

User Conferences:

Modernization, SAP, WMS

During a number of events, viastore systems will provide

information regarding modernization options, introduction

of SAP in the warehouse or new features of the

viad@t standard software for logistics managers, IT staff

and maintenance personnel in logistic facilities.

With the viastore User Conferences we offer our customers

the opportunity to learn about the latest viastore

topics. Here you can also exchange experience with other

users and discuss individual requirements.

For more detailed information, please contact

Info Service

If you wish to obtain further information about viastore or our systems, products and services,

please do not hesitate to contact us at or fax this coupon to +49 711 9818-184.

Company Profile S/R Machines Cold Storage Freezer HPPS

Small, Compact

Warehouses (German)

Warehouse Management

System viad@t

Logistics Execution

with SAP

viastore systems GmbH · Magirusstr. 13 · 70469 Stuttgart · Tel.: +49 711 9818 - 0

viastore systems Inc. · 4890 Kendrick SE · Grand Rapids MI 49512-4048 · Tel.: +1 616 977 3950

viastore systems S.A.R.L. · 31 Allée du Grand Coquille · F-45800 St.-Jean-de-Braye · Tel.: +33 2 38 61 98 60

viastore systems B.V. · Elektrostraat 17 · NL-7483 PG Haaksbergen · Tel.: +31 53 57 43861

viastore systems S.A. · c/Paletes, 8 Edificio B · Parc Tecnològic del Vallès · E-08290 Cerdanyola · Tel.: +34 93 59 10 ^


viastore systems s.r.o. · Dopravni 139 / 33 · CZ-318 00 Plzen-Nová Hospoda · Tel.: +420 377 495 406

viastore systems Ltd. · Westgate Lodge · Low Street · UK-North Wheatley, DN22 9DS · Tel.: +44 142 788 30 12

000 viastore systems · Odinzovo area Barwichinskij Selskij district, 1st km, Rublevo-Uspenskoye shosse · Building no.: 6

Office 301-2 - RUS-143082 · Moscow Region · Tel.: +7 495 663 2124

Please send us the following brochure(s):

Please send us references from the

following sector(s):

Basics of Warehouse

Technology (German)

viad@tACADEMY Racking


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Lifetime Partnership

intralogistik News 2|09 11


Warehouse software at a glance

New viad@t brochure out now

viad@t is a modern, efficient, well-proven and future-proof

standard software for managing and controlling all types of

intralogistic systems. The software offers

versatile functions both for small warehouses

with low turnover and for large

distribution centers with several thousand

orderlines a day. In addition, it is equally

suitable for highly automated systems as

well as conventional or forklift served

facilities. The WMS is multilingual and

works independent of databases, operating

systems and hardware. Based on 40

years of intralogistic experience, viad@t is

a stable product that can be easily configured

and upgraded.

viad@t consists of a basic package, having

functions that can be turned on or off,

depending on the specific demands, system

type and performance requirements.

Thus the WMS can be used for complex systems with high performance

capacity, for automated warehouses with low to

medium turnover rates and also for conventional warehouse

areas and logistics centers. viad@t is a highly flexible warehouse

management system that will adapt through the years to a

company's growth of business, changing demands and new


The new viad@t brochure describes the versatile functions and

application options of this flexible warehouse management software

in a well-structured and reader-friendly manner with

accompanying detailed charts and tables. The brochure can be

ordered at

12 intralogistik News 2|09


viastore systems intralogistik News

Publisher and responsible for contents: viastore systems GmbH,

Magirusstr. 13, 70469 Stuttgart/Germany, Tel. +49 711 9818 - 0

Editors: Dr. Matthias Schweizer (responsible),

Götz Bartling, Katrin Freese, Angelika Waizenegger

Volume 10, Edition 2/2009

viastore systems intralogistik News is published three times annually.

Production: Atelier Herbstreuth, Stuttgart

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