Dynamic solutions
February 1st 2007

In a prime example of its passion for excellence and innovation, Bosch has embraced dynamic storage solutions from Interroll in the production and assembly processes at its plant at Hildesheim, Germany

Automotive components manufacturer Bosch supplies electrical and chassis components which can be found in virtually every part of the onboard power systems of cars. Bosch components are involved in everything from the generation and distribution to the utilisation of electrical power in vehicles. The company's full range of electronics and software is developed, manufactured and organised in-house. This includes a new power steering system of the joint venture ZF Lenksysteme, for which Bosch Hildesheim produces over three million actuators per year.

Dynamic components The Bosch Production System (BPS) formed the basis for the design and implementation of the system. The aim here was to ensure streamlined production with optimum materials handling and the shortest possible through-put times.

Alexander Farnkopf, production manager for steering drives, describes the approach deployed by Bosch: "Using various BPS modules, including those from the Value Stream Design, we were able to design a production process which exactly met our requirements." Three Interroll-designed dynamic flow systems – which do much more than simply store goods – were integrated perfectly into the Value Stream Design, thus covering the full range of activities from goods receipt to dispatch.

The pull principle The pull principle: all deliveries of components are received at two goods inwards ramps and transported by forklift to the direct delivery warehouse. This warehouse is divided into two pallet flow systems which are upstream of stator production and final assembly. After the plastic pallets have passed through, staff pick the required parts from the storage block, thereby replenishing the production units. A third storage block is located between the two production areas and is used as a reserve or buffer. This buffer is used to control production using the pull principle.

The overall result is that stator production only takes place when there is a gap in the buffer caused by removals. Thus, stator production is governed entirely by final assembly.

FIFO and other good reasons According to Alexander Farnkopf: "The uncomplicated way in which the warehouse is managed and the successful implementation of the FIFO principle were just two of the key reasons for implementing the Interroll dynamic flow system within the steering drive unit." Together with racking partner and system integrator Saar Lagertechnik GmbH, which provides rack systems, Interroll was able to meet the challenge of devising a system based on streamlined design and rapid implementation. Moreover, the dynamic flow systems can be deployed within a nonautomated environment, which makes them the perfect choice for smaller operating units.

One type fits all The requirements for the actual modules within the dynamic flow system posed quite a challenge. Take pallets for example: "When moving components to the assembly station, we need a certain degree of precision when it comes to pallets. This is why we had special plastic pallets manufactured," explains Farnkopf. Interroll assessed the special Bosch pallets in a series of tests and came up with a tailor-made solution that allows different types of pallets to be used in the same dynamic flow lane.

Construction of the lane involved the special positioning of rollers and the deployment of speed controllers in a specific manner, thus ensuring the safe and controlled movement of goods.

Interroll flow storage technology One of the new flow storage products, Interroll Flex Flow, is predestined for tasks in which speed and precision are of the essence, e.g. at assembly lines in the car manufacturing and automotive supply industry. Without compromise this combined storage, conveyor, and picking rack designed for Kanban systems, and thus dynamic operations, takes to these tasks like a duck to water. Stationed in close proximity to the actual production or assembly point, Flex Flow ensures the best possible use of space, a streamlined chain of supply, as well as ergonomically structured storage and picking processes.

The result: reduced distances, efficient use of floor space, an improved picking performance of up to 75%, full compatibility with other rack systems, exemplary technical reliability, superior safety for personnel and goods, as well as future-proof technology and fast return on investment.

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