The client

  • Alfred Kärcher GmbH & Co. KG, D-Winnenden
  • Cleaning systems, products and services for recreation, household, trade and industry

The project

  • Worldwide Spare Parts Distribution Centre
  • Distribution channels: Multichannel B2B/B2C
  • Go-live: October 2013

Delivered results

  • Consolidation of several satellite distribution centres
  • Optimized customer service level by reducing order lead times down to 30 minutes
  • Synchronization of four different picking areas for SKUs of different sizes with higher pick rates through goods-to-person process
  • Storage capacity increased by 40 %
  • Operators’ productivity increased by 100 %
  • Reduced picking error rate (> 10 % → < 0.01 %)
  • ROI < 3.5 years

Design Figures

Number of SKUs

  • 67,250 in total
    • 62,250 spare parts
    • 5,000 accessories

Throughput - Order lines

  • 2.8 million order lines per year
  • 150,000 order lines per month - peak: 300,000
  • Average order lines per order: 3

Operation

  • 2 shifts

Installed Systems

Warehouse type(s)

AS/RS (Miniload)

Consolidation buffer

Pallet high bay
warehouse

Manual pallet
warehouse

Number of aisles/blocks

8 aisles

2 aisles - 36 levels

5 aisles

 

Number of storage locations

95,000

5,500

 

 

SRM type(s)

8 x Mustang

36 x Stingray, double Spectra lift

5

 

SRM throughput

 

  • 1,800 double cycles per hour

 

 

Number of workstations

  • 8 ergonomic goods-to-person pick stations 2 : 1 (2 source totes: 1 target tote)
  • Best ergonomics through tilted totes
  • Picker guidance via visualization and light signals

Footprint

  • 20,000 m²