Automotive supplier makes its logistics operation leaner and faster with WERMA

Continental based in Regensburg Germany is the location for the Group’s largest electronics manufacturing business.

The Supply Chain centre established in 2001 processes around 1,500 goods inward receipts and 390 despatches per day.  Employing an automated handling system and optimised handling between manufacturing and warehouse the “Just in Sequence Logistics” system offers the best in safety, reliability and quality.

The principle of “Just in sequence” (JIS), itself a development of “just in time” is being deployed more and more by supply chain management and automotive suppliers in general.  It ensures that quite simply the right parts are delivered to the right location in the right sequence of the manufacturing process.

12 electric AGVs transport material from warehouse to manufacturing on floor guided tracks continuously in a process where the optimum time from requesting material to delivery line side is set as one hour.

The 130 m long track between warehouse and manufacturing is under the surveillance of a kind of black box idea, as all along the track the status of the AGV is unseen and unknown.  If there should be a breakdown on the track in the past it could take up to 10 minutes for the AGV controls to report back the breakdown.

Mathias Meier Team Coordinator Industrial Engineering at Continental had been searching for a solution for some time.  “Working on JIS principals means that every minute we lose on the track is costly”.  During a Lean Workshop roadshow the Regensburg team became aware of the WIN system offered by WERMA ordered a kit to trial on the line. “It was so simple to install without any prior knowledge and was up and working straightaway”comments Meier.

The key to the solution is the signal tower fitted to each AGV which acts as the interface.  A transmitter element is simply fitted to a WERMA signal tower with its unique twist and fit locking arrangement. The transmitter transmits the status change of either of the lights on the tower instantaneously to a receiver unit connected to the network or hosted by a local PC.

In the installation at Regensburg the receiver is connected directly to Mathias Meier’s PC and whenever there is a breakdown on the line he receives an immediate warning notice on his screen.  The system will also deliver an e-mail message to staff on their smart ‘phones advising them of the breakdown, enabling them to react to and resolve the issue.

Meier has been very pleased with the positive developments since the introduction of the WERMA WIN system. “It is clear that one of the big advantages of the WERMA system is the speed – we get notification of a breakdown immediately as it happens.” The data collected by the system is held on an integral database supplied with the software.  The comprehensive software modules offers comprehensive analytical and report creation possibilities as well as excellent visual displays.

Meier comments on the ease of installation and operation of the system, “The WIN software and step by step installation guide make it really easy for anyone to install.” No programing knowledge is required to install the software.

In addition Meier was very pleased with the investment cost required –“the complete system cost about £3000 compared with other systems which would have cost between £20,000 and £30,000”.

Improve transparency, increase productivity, become more flexible, reduce breakdowns as well as saving time and money are just a few of the advantages of the WIN system from WERMA.  In no time at all Continental were able to improve