Intralogistics refers to the management and optimization of internal logistical processes within a company. It means the movement, storage and handling of components, materials and information. The aim is to design, implement and control efficient and effective systems to ensure a smooth flow(lean process) of resources along the entire supply chain. This begins with the procurement of raw materials through to the delivery of finished products.
ZELL has taken on the challenge of developing systems
that do not require recharging operations.
For example, the component only has to be positioned once in a workpiece carrier or industrial cleaning basket after processing(cleaning blasting, etc.) and can then remain there until finished processing.
As a rule, an industrial product cannot be manufactured on a single machine. Already in the production hall, it is transported over several stations. In addition, there are external production sites or service providers that have specialized in the manufacture of certain subcomponents or machining processes. Intralogistics tries to find the best solution for the overall process.
On the right in the example, a workpiece is first machined and then stored in the logistics center. This is followed by special surface treatment (e.g. shot peening) before the component is transported via the logistics center to final assembly and then shipped as a finished product.
The example also immediately shows the need for packaging between the individual production stages (red). The company must make the parts ready for transport in order to ensure the quality of the elaborately manufactured parts. This sometimes requires personnel, time and disposable packaging. Three decisive cost factors!
With an innovative workpiece carrier system, these three cost factors can be sustainably saved. Modular containers are particularly suitable as conveyors.
With the implementation of a workpiece carrier system, the above intralogistics example changes to the following simplified process:
The component is no longer handled individually, but inserted directly into a suitable workpiece carrier for production logistics. The component can then be processed fully automatically. After the first production stage, the workpiece carrier is placed in the matching basket and sealed. In this way, all components can be secured for transport.
From now on, only the complete system is handled. ZELL systems even allow washing in the industrial cleaning basket without component removal. Only the finished product is removed and picked at the end of the process. The carrier system can then be conveyed back in one cycle. This results in"sustainable intralogistics".
The industry has numerous means of conveyance in the transport of workpieces. These include: Automated Guided Vehicles (AGVs), autonomous mobile robots (AMRs), classic conveyor systems, automated storage and retrieval systems (AS/RS), and finally, intelligent container or workpiece carrier systems.
At ZELL, the transport containers consist of three important components: (1) clip/multiclip for optimal workpiece pick-up and protection of the sacrificial surfaces, or plastic baskets when transporting bulk goods. These are mounted on a suitable (2) workpiece carrier made of plastic or stainless steel and finally inserted and closed in a (3) basket.
The entire workpiece carrier system can be easily moved on all common conveyor tracks and has defined fixed points for intralogistics automation. Optional marking holders can be attached for QR codes and RFID.
Automated intralogistics
With the integration of Industry 4.0 technologies, intralogistics is undergoing a revolutionary transformation that will lead to increased efficiency, productivity and competitiveness. ZELL supports this development with intelligent carrier systems.
The main pillars of Intralogistics 4.0 are networking, data analysis and artificial intelligence. In the field of intralogistics, these technologies are revolutionizing conventional manual processes. Networked containers provide real-time data on stock levels, logs and environmental conditions (through Internet of Things (IoT) sensors).
With a defined matrix on the carrier, ZELL offers manufacturers the ability to know where which component is in real time. Workpiece carriers and industrial baskets become uniquely identifiable with RFID or scanning of bar/QR codes. In this way, autonomous intralogistics can be realized which, in theory, no longer require manual intervention.
This data enables proactive decision-making, reduces downtimes and enables the forward-looking digitalization of intralogistics.
There are many levers to improve intralogistics processes. ZELL has focused strongly on container management. The flexibly adaptable carriers and baskets offer intralogistics a wide range of possibilities. Label holders enable communication in accordance with Industrie4.0, allowing all containers and components to be controlled in real time. The data that is generated helps to better understand the material flow and to make adjustments for intralogistics and quality management.
Optimization of intralogistics transport systems
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