Increased challenges and necessary adjustments to their existing system kicked off a dialogue between Klebchemie M.G. Becker GmbH & Co.KG, based in Weingarten, Baden, and iFD GmbH. With the existing warehouse control system, adaptations could only be implemented to a limited extent, so that in February 2020 iFD recommended a modernization and thus future-proof replacement of the existing system.
For more than 70 years, Klebchemie M.G. Becker GmbH & Co.KG (brand name Kleiberit) has been developing, producing and selling glues, adhesives, PU foams and sealing compounds for the national and international market. Customers are the furniture and wood industries, craft businesses as well as the automotive, construction, filter and textile industries. The annual output is approx. 60,000 t and the company employs approx. 660 people worldwide.
The core of the logistics system to be controlled is a four-aisle high-bay warehouse (HRL) for shipping with one stacker crane (RBG) in each aisle. For storage and retrieval, a pallet conveyor system works together with several vertical and horizontal conveyors. Two picking stations are used to prepare the goods for shipment to the customer.
In addition, production is connected via various conveyor lines. Produced palletized goods that have to be kept in stock for picking and shipping are automatically stored in the high-bay warehouse.
The warehouse control system (MFCS) from iFD is very well suited for modernization or retrofitting of existing plants. Besides the future-proof replacement of an old system, it increases the conveying capacity through improved strategies and homogeneous load distribution. In addition, the new material flow system offers many add-ons and expansion options, for example, in the case of expanding an existing system with additional storage areas or spaces.
The iFD MFCS is tested with the integrated plant simulation through proven operating scenarios and thus guarantees stability in productive use.
The jointly developed implementation concept was provided for only short-term downtime of various plant components during the weekend. This significantly shortened the commissioning period and minimized the risk of downtime.
Thanks to the cooperative partnership between the two companies and this approach, the retrofit was completed within a very ambitious schedule while ensuring continuous 24-hour production.