Expansion of the existing system.
Low Error Rate
Boldly Into
The Future
Kellner & Kunz AG is part of the international RECA Group.

Expansion of the existing system

THE 
GOAL:
LOW ERROR RATE

The benefits: greater speed, higher productivity and a decrease in the error rate of more than 50 percent. In collaboration with Kellner & Kunz, a company of the RECA group, we successfully applied various levers to achieve these targets in automation. Due to its high growth rate, the company again decided to expand its system again it 2019 and turned to us a partner.

Background Grid
AT A GLANCE
challenges
mastered
  • POWERFUL COMBINATION of automatic mini-load warehouse and shuttle system

  • HIGHER THROUGHPUT as basis for efficient delivery

  • SIGNIFICANTLY INCREASED STORAGE VOLUME

  • MASSIVELY REDUCED ERROR RATE

  • FULLY AUTOMATIC DISPATCH + SORTATION SYSTEM for fast supply of B2B and B2C customers

ABOUT KELLNER & KUNZ

The company is known primarily for its high-quality tools of the proprietary RECA brand. Kellner & Kunz AG is part of the international RECA Group and one of the leading providers of tools, fastening systems and C-parts. The company's primary client base consists of industrial customers and trade shops. These companies are supplied with everything they need. The headquarters in Wels supplies customers in Austria and Europe with over 120,000 articles.

Erweiterung der Bestandsanlage für Kellner und Kunz
INITIAL SITUATION
FUTURE 
SUPPLY CHAIN 
STRATEGY

The growth made it difficult to boost productivity using existing logistics structures. The company first decided in favour of a TGW solution back in 2007, when it opted to give up the external warehouses and set up its own logistics centre.

At the same time, the objective was to push the complete integration of the supply chain and increase the storage volume significantly. Furthermore, the idea was to discontinue processes with paper documents and replace them with digitalised workflows – with the goal of cutting the error rate while boosting productivity. Finally, a fully automatic dispatch and sortation system for fast supply of B2B and B2C customers was required.

To lay the foundation for continuous growth, Kellner & Kunz again chose TGW as its intralogistics partner. For the purpose of expanding the existing system with a highly automated solution, the Wels facility is now getting a powerful combination of automatic mini-load warehouse and shuttle system.

SOLUTION & MATERIAL FLOW

 

GOODS RECEIPT & STORAGE

The products are delivered both on pallets and in packages and prepared for storage at state-of-the-art workstations. In addition, there are workstations for replenishment from the high-bay warehouse. The extensive automation project contains an automatic tote warehouse, an automatic pallet warehouse, an automatic tray warehouse and tote picking system that works according to the person-to-goods principle

 

PICKING

To get super fast-moving items out of the logistics centre as quickly as possible, up to 20 order-picking stations are available. They are supplied with two Mustang storage and retrieval machines. In this area, there are a total of 1,900 positions for totes and 2,800 storage positions in the flow channel.

 

PACKING

There are a total of 16 workstations for filling packages. There, 700 packages per hour can be cycled through. The employees can prepare up to 45 pallets an hour for shipment.

 

CURRENT EXTENSION

The automatic miniload warehouse is equipped with 15 Mustang Evolution SRMs in anti-sway design. The solution is being expanded by adding a shuttle system. The implementation likewise includes six high-performance order picking workstations

HIGHLIGHTS

RETROFIT

The expansion was achieved without effecting the ongoing operation (retrofit). The Kanban supply was adapted and the C-parts management services were implemented to meet current customer requirements

The expansion without effecting the ongoing operation - Retrofit.

LIFETIME SERVICES 10-YEAR SERVICE CONTRACT

A 10-year service contract (remote customer support, on-site technicians, maintenance, genuine parts management) ensures maximum system availability with transparent and predictable costs. Kellner & Kunz is able to concentrate on its core processes while onsite TGW engineers work proactively on maintenance and continuous improvement of the system. The tools manufacturer benefits from cost transparency and low Total Cost of Ownership.  

A maximum system availability with transparent and predictable costs.

KEY FIGURES

  • SKU's: 120,000
  • Order throughput: 2,800 per day, up to 16,000 items
  • Shipment throughput: 2,800 packages and 360 pallets per day
  • Fully automatic dispatch and sortation system: 700 packages and 36 pallets per hour
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Erich Schlenkrich Kontakt
Erich Schlenkrich
Industry Manager Industrial & Consumer
TGW Logistics Group GmbH
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