Intergrated approach
March 1st 2008

Jungheinrich UK's Systems & Projects Division integrates materials handling systems to create a effective warehouse operation. It has recently helped Häfele with an integrated mini-load and order consolidation system

In the region of 20% of Jungheinrich's turnover – which, in the current financial year, is expected to top two billion euro – comes from multi-product projects and systems integration.

"Having a wide range of products – from pallet trucks to conveyor systems – in the marketplace has certainly contributed to our success, but products alone do not automatically guarantee the most efficient or optimised solution," says Steve Richmond general manager of Jungheinrich UK's Systems & Projects Division.

Steve Richmond continues: "Material handling systems integration is, by definition, the bringing together of multiple technologies in an interconnected system and delivering successful integrated projects (regardless of every size) demands expertise across a whole spectrum of materials handling equipment – including conveyors, forklift trucks, very narrow aisle (VNA) equipment, stacker cranes and racking as well as warehouse management systems (WMS) and automated guided vehicles.

Jungheinrich UK's Systems & Projects Division has recently been awarded a major contract to supply an integrated mini-load and order consolidation system to Häfele UK – a leading international supplier of furniture fittings, architectural hardware, electronic locking systems and technical hardware advice. A conveyor system is at the heart of the operation.

Valued at over £1.6million, the order is the latest phase in the development of a highly automated operation at Häfele's UK distribution centre in Rugby, Warwickshire.

The facility is thought to be the biggest furniture fittings and architectural ironmongery store in the UK and Jungheinrich has partnered Häfele on the project for over 10 years.

At the Häfele store empty target totes are stored in the mini load system and delivered to four picking zones. Part orders are then delivered by tote conveyors to the picking zones. When an item is scanned, a "reverse" pick to light system indicates which of the dispatch totes the item should be placed into. This process continues until the complete customer order has been consolidated. The tote is then picked up by one of the mini load cranes and taken to a take-off conveyor and transported to the dispatch area.

The various items are them consolidated into customer orders ready for dispatch using a reverse pick to light system. The completed orders are then automatically transported to the dispatch area from where they are sent to Häfele's clients, who include interior fitters, hardware dealers, building investors, architects, planners and local authorities as well as companies in the furniture industry.

"Projects such as the Häfele facility really do require clear thinking and a competencebased approach from the integrator and this latest installation will enable the company to bring further financial and operational efficiencies to what is already a highly automated high-bay warehouse."

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