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Honold has taken over the operation of the central logistics center with the functions of inbound and pre-product logistics for the production supply of the ZEISS divisions in Oberkochen. Honold employs over 50 people on an area of around 10,000 square meters. The fulfillment of the requirements is complex: 3-storey shelf storage, heavy and oversized shelves, several climatic zones, block storage, external storage, shuttle transports are represented by Honold. The unwinding range of materials with approx. 30,000 different material numbers ranges from highly sensitive lenses with a diameter of 5mm to cleanroom-packed precision components to granite blocks with 25 to. The project’s aim is to supply the ZEISS production with regard to throughput times, costs and quality optimize. The warehouse operates in a two-shift operation, which can be expanded to 7/24 if required.
A particular challenge is that several different areas of ZEISS have to be supplied on a just-in-time basis with completely different logistical requirements and strategies. This means a throughput time from receipt of order to goods issue in the logistics center between one and three hours – with an error rate of <0.3%. The volume fluctuations amount to ± 30% per day depending on the production plan.
In order to take into account the wide and sensitive range of materials, the handling is done partly with tweezers and gloves in the dust-free area, but also by using a 25to. Crane system. Multi-level order consolidation, kit building and Kanban processes, rush orders, cross docking and value added services were implemented systematically. For the start, a cross-organizational team of partners Honold and ZEISS was formed, which realized the commissioning of the logistics center within 12 months. For the IT implementation of the Honold SAP EWM solution alone, more than 300 man-days were necessary. As part of the implementation, the data center of Honold was also reorganized and meets all requirements for safety and environmental protection. The total investment volume of Honold amounts to more than € 4 million.