Semi-automatic for the people
February 1st 2009

Jungheinrich launched its new vertical order pickers last month focusing less on the trucks and more on total process optimisation. Alongside the new 210 and 310 EKS models, the firm demonstrated its broader approach to picking, and indeed, total warehouse solutions. Brendan Coyne reports

The launch took place at agricultural giant Claas' parts logistics centre, near Hamm in the industrial heartland of Germany. An apt choice given that Claas, best known for its combine harvesters (it is European market leader), must achieve highest possible accuracy.

"Parts availability is vital because our customers' working period is very short," says Claas Parts Logistics boss, Norbert Wiehoff. "Combine harvesters work approximately 17 days a year, therefore even one day of downtime creates massive problems." Using Jungheinrich's new trucks and warehouse intelligence systems, CS Parts Logistics reports a 'significant' improvement in picking efficiency.

Smoother operators The site has been using Jungheinrich's new reach stackers for several months (and other kit, such as the EKX Kombi VNA stacker, for even longer) in conjunction with the firm's RFID-based control solution.

Transponders spaced 10 meters apart along each aisle enable CS Parts Logistics to hone operations and improve safety. For example, the truck automatically stops at the end of the very narrow aisle, before allowing the operator to creep the truck into the main aisle, helping prevent accidents. It also uses Jungheinrich' Personnel Protection System, a laser mounted at the front of the truck, at ground level, that detects objects in the truck's path, slowing the truck and stopping if the obstruction remains.

But Jungheinrich has sold this kind of solution since it launched the VNA turret truck, the EKX in 2007 (of which Sebastian Riedmaier says there are 1,500 in operation). Now however, it has integrated an improved picking solution that basically semi automates the picking process using intelligence enabled by adding RFID to achieve warehouse 'GPS' tracking to guide both truck and operator. According to Riedmaier, it can improve operator picking productivity by up to 25 per cent. Not a man given to hyperbole, however, he explains his claim applies to less experienced drivers. Average drivers, he says, will see around 10 per cent efficiency gains. But he says even the best drivers will improve around 5 per cent.

A touch screen integrated into the cab tells the operator which item to pick, and its aisle position. But, given that the WMS knows the part's precise location, the driver merely has to drive the truck forward, lifting simultaneously, and the truck stops at the parts exact location. Lights are mounted on both sides of the cabin. These tell the driver which side of the aisle to pick from, and he simply points a laser scanner integrated into the truck at the correct barcode, confirms the pick on the touch screen, and the WMS then instructs him where to go. Essentially, this means the driver can operate at full speed, stopping automatically at the right place without having to think or look for the location. Travel distance over both height and distance is optimised, speed is increased. And accuracy is guaranteed because the system will not give the operator another picking instruction until the correct pick is confirmed.

Craig Johnson says the increasing need for faster lower level replenishment is behind the development of the new trucks, and increasingly, the intelligence Jungheinrich is adding to its warehouse control systems. "Jungheinrich is very strong in the low level order picking market, but, with working at height legislation and the ever increasing importance of accurate picking, we see this as a growth area. Logistics firms, particularly FMCG and parts logistics, will see the benefit." Johnson also stresses that, because Jungheinrich designs and builds its own control systems at its Norderstedt plant, they are optimised for the specific application purpose built for process optimisation.

Steve Richmond, general manager of Jungheinrich UK's systems & projects division, expands on the benefits of building from the ground up: "Bolt-on systems have been around for a number of years but, when things go wrong, separate suppliers have a tendency to blame each other. This doesn't help the customer, who just wants everything to work. We see the future as an integrated approach: the trucks, the intelligence, and warehouse design and layout rolled into one. It's all about improving processes, however that can be achieved."

Intelligent picking While launching the new reach stackers, Jungheinrich also demonstrated its other new intelligent picking options using both barcodes and RFID. The barcode solution uses a truck mounted touch screen to tell the operator the pallet pick location. When he arrives at the location, a laser mounted at fork-level automatically scans the load's barcode, and the operator confirms the load.

The system, via the touch screen, then tells him where to put it. Once at the intended destination, he scans the racking location barcode using a hand held scanner mounted in the cab. He does this straight through the truck's windscreen, without having to lean out and scan, improving driver ergonomics.

If the incorrect location is scanned, the screen tells the driver, and will not give another picking instruction until the correct location has been found, scanned and confirmed.

The near future of RFID? Jungheinrich has also developed an RFID pallet picking solution, that Jungheinrich's Dr.

Martin Schwaiger, team leader, technologies, believes might just be 'the next big thing'.

Jungheinrich has integrated an RFID reader into a set of long forks capable of carrying two pallets. The antenna runs along the length of the forks, enabling it to read a tag implanted in the middle beam of the pallet.

When the operator picks up the load, a clear graphical representation of the pallet appears onscreen, prompting the driver to confirm the load. The system then tells him where to put it. Once the correct location is found and the load deposited and confirmed, the screen gives him a new instruction.

By placing the tag under the load, the problems radio frequency experiences with metals and liquids are negated, although Dr Schwaiger says metal pallets would not be compatible with the system. The ideal solution, he says, is RFID tags, implanted into plastic pallets. He believes RFID enabled pallets will soon emerge from their current confines in closed loop systems, driven largely by retailer mandates. "It is application specific, but I believe it is the future of RFID," says Schwaiger. "The near future." Both the fork-level laser scanner and the RFID enabled forks can be fitted to virtually any Jungheinrich truck. The touchscreen operator interface can be fitted to new trucks, while the RFID, barcode picking and warehouse positioning modules can be integrated into virtually any WMS, claims the firm. High on gas, low on cost

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