Optimizing Electronic Components Warehousing https://www.elementlogic.net/us/cases/category/electronic-components/ Thu, 11 Jun 2026 16:57:00 +0000 en-US hourly 1 https://wordpress.org/?v=6.6.5 https://www.elementlogic.net/content/uploads/sites/8/2024/11/el-favicon-512x512-1-150x150.png Optimizing Electronic Components Warehousing https://www.elementlogic.net/us/cases/category/electronic-components/ 32 32 Continental’s Story in Guadalajara, Mexico https://www.elementlogic.net/us/cases/continentals-story-in-guadalajara/ Wed, 08 Jan 2025 15:43:25 +0000 https://www.elementlogic.net/us/?post_type=case&p=2755 (Read Press Release). This state-of-the-art automated storage and retrieval system (ASRS) marks a new chapter in Continental’s pursuit of operational […]

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Continental’s Story in Guadalajara, Mexico

Continental, a global technology leader in automotive manufacturing and mobility solutions, took a significant step in advancing its warehouse operations by implementing AutoStore at its Periférico Plant in Guadalajara, Mexico.

(Read Press Release).

This state-of-the-art automated storage and retrieval system (ASRS) marks a new chapter in Continental’s pursuit of operational excellence and digital transformation.

Designed to optimize space utilization, enhance order accuracy, and improve productivity, the AutoStore system is a testament to Continental’s commitment to innovation and efficiency in its supply chain processes. With a focus on intelligent automation, the Guadalajara plant aims to set a new benchmark for streamlined operations in the automotive industry.

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Continental Video Case Study

Challenge

Continental’s Periférico Plant faced a critical challenge: limited floor space that constrained its ability to efficiently manage inventory and meet increasing demand. As the company continued to grow and diversify its product offerings, it became evident that traditional warehousing methods were no longer sufficient.

“We started in 2001 in Guadalajara, Mexico. With 23 years of experience here at the plant, we are looking for an increase in quality of life for our employees.”

Sergio Márquez, Plant & Location Manager at Continental

The need for a scalable solution that could maximize storage capacity without requiring additional floor space became a top priority. Continental sought a system that could adapt to their evolving needs while ensuring seamless operations and high productivity.

Solution

To address these challenges, Continental turned to Element Logic. AutoStore, an ASRS known for its unique approach to warehouse efficiency and organization, has a modular design which allowed Continental to maximize storage capacity by utilizing vertical space. This effectively overcame the plant’s floor space limitations. The system’s high-speed robots efficiently retrieve items from a dense grid of bins, ensuring quick access to inventory while reducing strainful manual labor.

From left to right: Fernanda Morales Witrago, Communications Specialist at Continental; César Rodriguez Valadez, Advanced SCM Project Manager at Continental; Santiago Corona, Videographer; María Elena Ladrón de Guevara, Director of Marketing – Americas at Element Logic, María Luz del Alba Pérez, Head of Plant Communication & Executive Assistant at Continental, Sergio Márquez, Plant & Location Manager at Continental; José Luis Quezada, Head of Plant SCM at Continental; Salvador Nuñez, Material Flow Manager at Continental; and Santiago Corona, Videographer.

“The transfer times we had before AutoStore were much longer than they are today. We could not be happier with the performance. We have increased delivery of materials, both internal and external, by 67%”

Salvador Nuñez, Material Flow Manager at Continental

By implementing AutoStore, Continental was able to streamline its operations with an automated solution that enhanced inventory management, improved order accuracy, and increased overall productivity. The flexibility and scalability of AutoStore also meant that the system could be easily adapted to meet future growth, providing a long-term solution to Continental’s evolving warehousing needs.

Impact

The implementation of AutoStore has had a transformative impact on Continental’s Periférico Plant, driving both operational and employee-centric improvements. By optimizing storage capacity and automating repetitive tasks, the system has enabled Continental to handle larger volumes of inventory and meet customer demand more effectively. Order processing is now faster and more accurate, reducing errors and improving customer satisfaction.

“… we have greatly increased our security levels- which is a very important issue for Continental”

José Luis Quezada, Head of Plant SCM at Continental

“Continental has seen quite a few improvements.” José Luis Quezada, Head of Plant SCM at Continental said. “Once we implemented AutoStore, we began optimizing our resources as well as optimizing the workforce we have here. Additionally, we have greatly increased our security levels- which is a very important issue for Continental”

For employees, the shift to automated processes has significantly enhanced their quality of life. Tasks that were previously labor-intensive and physically demanding have been replaced by automated systems, reducing the risk of injuries and allowing staff to focus on more value-added activities. This has created a safer and more engaging work environment, fostering higher employee morale and job satisfaction.

Overall, AutoStore has equipped Continental with a future-proof solution that supports the company’s growth ambitions. The Guadalajara plant is now better positioned to scale operations, adapt to market changes, and continue delivering high-quality products efficiently and accurately. The successful integration of AutoStore underscores Continental’s commitment to innovation and operational excellence in a highly competitive industry.

Results

“Continental was looking for a highly efficient solution in a limited amount of space that would allow them to protect their products from debris.” Cristian Ahumada, Director of Operations – LatAM at Element Logic said. “Furthermore, they wanted a solution that had high processing rates. For all these reasons, AutoStore was the ideal solution for them.”

… AutoStore was the ideal solution for them.

Cristian Ahumada, Director of Operations – LatAM at Element Logic

Element Logic’s successful implementation of AutoStore at Continental’s Periférico Plant has delivered impressive results. The system has significantly increased space optimization, allowing Continental to make the most of its available warehouse area. Speed and efficiency have also improved, enabling faster order processing and reducing lead times. Additionally, the AutoStore system has proven to be highly reliable, ensuring consistent performance with minimal downtime. Its flexibility and scalability ensure that the system can adapt to future business needs, providing Continental with a robust and sustainable solution for long-term success.

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Electronics giant Power expands its AutoStore from Element Logic https://www.elementlogic.net/us/cases/electronics-giant-power-expands-its-autostore-from-element-logic/ Thu, 22 Aug 2024 13:35:34 +0000 https://www.elementlogic.net/?post_type=case&p=715 At POWER, the aim is to stay ahead with well-considered, efficient solutions, keeping prices low while providing customers with the […]

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Electronics giant Power expands its AutoStore from Element Logic

Power is the electronics giant of the Nordic region with almost 268 stores spread across four countries. As it takes over all Mediamarkt stores in Sweden, the company has reviewed its increased needs and is consequently expanding its automation solution from Element Logic.

At POWER, the aim is to stay ahead with well-considered, efficient solutions, keeping prices low while providing customers with the best shopping experience. Therefore, the company invested in automation early, building their current AutoStore in 2017. In 2020, they did a renovation of their storage ports for better ergonomics and in 2021, they added two more ports. After five years of successful operation, they expanded in April 2022 that doubled Power’s AutoStore.

New market demands new solutions

As Power takes over all former Mediamarkt stores, their warehouse and logistics solution needs to keep up with the new conditions in the Swedish market. The expansion is linked to an expected growth increase through the establishment in Sweden, but also an organic growth in the other countries.

Power already has an AutoStore with roughly 46,000 bins, 54 robots, and 13 ports. They are making room for an additional 40,000 bins, installing 10,000 initially, in addition to 24 new R5 robots, 7 new conveyor & carousel ports, and a picking tunnel. This means they have nearly full automation, from when the order comes in until the order is dispatched, except for the manual picking process.

Development Manager at Power, Casper Ödeen, says that over the past six years, Power has invested in automation and digitization of their processes. In addition to AutoStore, peripheral equipment has also been in focus for box erecting, sealing, and labeling. A robot for pallet building has been invested in, but it would not have been possible without AutoStore’s efficiency and scalability, which allows the automation to grow with the organization, he says.

All our investments, which we make in cooperation with Element Logic, mean that our employees can have a better working environment and we can spend our time on what creates value for the customeru0022

Casper Ödeen, Development Manager at Power.

“Power is far ahead in their automation. They were early with AutoStore, and they have chosen to invest in extended automation to be efficient, secure a stronger delivery to their customers, while also achieving improved ergonomics,” says David Olsson, Account Manager at Element Logic, Sweden.

Power’s expanded AutoStore facility went live in May 2023.

Facts and figures:

  • 10,000 new bins (making room for 40,000 new bins)
  • 24 R5 robots
  • 7 new conveyor & carousel ports
  • One new picking tunnel

Want to learn more about optimizing your warehouse?

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Robotic arm connected to AutoStore at Solar https://www.elementlogic.net/us/cases/robotic-arm-connected-to-autostore-at-solar/ Thu, 22 Aug 2024 13:27:55 +0000 https://www.elementlogic.net/?post_type=case&p=642 In 1919, a young visionary from Denmark predicted how industrialization and electrification would create a need for electrical components and […]

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Robotic arm connected to AutoStore at Solar

After implementing AutoStore in 2018, Solar’s picking productivity skyrocketed. Now they are the first customer to put the robotic piece-picking unit eOperator into a production environment.

In 1919, a young visionary from Denmark predicted how industrialization and electrification would create a need for electrical components and created Solar. The company is now listed, counts 3.000 employees, and has subsidiaries in five countries.

Over a hundred years after the startup, Solar still embraces that same visionary spirit and is a firm believer in adopting new technology. With this attitude, combined with Solar’s major selling point in having fast and precise deliveries, it is natural for them to become the first to connect their existing AutoStore solution with Element Logic’s robotics piece-picking technology, eOperator. This makes Solar one of the world’s first to automate piece-picking this way.

Modernizing with eOperator

“The demands for efficiency and development are high, and at Solar, we wish to be a part of the robotic and technical development,” says Sondre Ressem, VP Operations at Solar.

eOperator, Element Logic’s robotic piece-picking unit, has now been in operation at Solar’s warehouse in Norway for a couple of months. It picks customer orders from the carousel port in AutoStore directly into packages ready to be sent out to customers.

The demands for efficiency and development are high, and at Solar, we wish to be a part of the robotic and technical development

Sondre Ressem, VP Operations at Solar.

“We wanted eOperator to keep up with the developing trends in society. Our goal is to keep growing while also focusing on costs, efficiency, sustainability, and digitization. To do this, we need to adopt new technology – new technology that can help us in our daily work and production,” Ressem says.

A milestone installation

“The pressure on supply chains today is massive. That is why we created eOperator to help our customers be even more efficient through automation,” says Henrik Berglund, business developer at Element Logic.

Berglund has been responsible for the development of eOperator and explains that the Solar installation is a milestone.

“Now it is at work in a real warehouse, in a production environment, handling real customer orders, and operated by Solar’s warehouse staff. The numbers of pickable products and picking performance are also exceeding our expectations”, Berglund says.

Scalability, and giving customers the ability to grow with the system is a major reason for choosing Element Logic as your automation partner.

“eOperator provides us with another tool in the scalability toolbox. For many customers this will be the next natural evolution of their automated warehouse“, Berglund explains.

The pressure on supply chains today is massive. That is why we created eOperator to help our customers be even more efficient through automation

Henrik Berglund, business developer at Element Logic.

eOperator – the next level of automation

“We were the first to implement AutoStore in warehouses, and now we are the first to successfully integrate the eOperator”, Niklas Top Aanesen, key account manager in Element Logic Norway, explains.

The addition of the eOperator makes Element Logic able to create even more efficient and reliable automation solutions for customers across a wide range of industries and sizes. It allows customers to increase order capacity, goods handling, and fulfillment speed.

We were the first to implement AutoStore in warehouses, and now we are the first to successfully integrate the eOperator

Niklas Top Aanesen, key account manager in Element Logic Norway

“The robotic arm can see a new product and attempt to pick it up without any preprogramming for that specific item. In other words, our customers do not need any preparation work to expand their product portfolio,” Aanesen says.

EL_Solar_eOperator_robot_3
INTELLIGENT: Using machine learning, the eOperator learns from a mistake and automatically finds the best way to pick the item.

Automated picking – integrated with AutoStore

eOperator helps Solar in their daily production, explains department manager Dan Espen Kvale.

“The installation was plug and play, and the feedback from the warehouse workers is that it is easy to use,” Kvale says. “With this robotic arm, we are further developing the AutoStore solution and are at the technological forefront of our industry.”

EL_Solar_AutoStore_robots
EVOLUTION: eOperator lets Solar yield even more efficiency from their AutoStore solution.

The robotic arm works at a carousel port in a tunnel under the AutoStore grid, blending right in between warehouse workers on other picking stations. It is surrounded by conveyor belts transporting packages to the entrance of the warehouse.

“It works really well. We are interested in further development and to see if we can include even more robot arms in our production,” Ressem says.

This is eOperator

eOperator is Element Logic’s robotic piece-picking technology, or robot arm solution. It is developed to work with AutoStore to automate warehouses further. eOperator increases order capacity, goods handling, and fulfillment speed with machine learning technology and creates a link between AutoStore and the material flow handling solution.

The arm is based on hardware from the Boston-based robotics company Right Hand Robotics. For two years, it has gone through rigorous testing and constant development by Element Logic’s R&D department to become the solution it is today. With its software eOperator can communicate with any WMS software, AutoStore robots and our eManager software.

Warehouse workforce initially skeptical

“A few employees were skeptical in the beginning, worried whether the robotic arm would take over their tasks. However, after working with it for a while, they see that it improves their daily work,” Kvale says.

“Getting access to new technology and developing new skills does something with our employees. They think it is exciting to work with cutting-edge technology,” Ressem adds.

EL_Solar_warehouse_worker
WORKING HAND IN HAND: Solar’s super-user Eva has been working with eOperator lately.

Facts and figures:

  • 1.150 m2 grid (3 772 ft2)
  • 40 Red Line robots
  • 1 eOperator
  • 35.000 bins
  • 12 Carousel ports
  • eManager
Element_Solar_collage

Want to learn more about eOperator?

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Automation in production gives a competitive advantage https://www.elementlogic.net/us/cases/automation-in-production-gives-a-competitive-advantage/ Thu, 22 Aug 2024 13:25:38 +0000 https://www.elementlogic.net/?post_type=case&p=627 There were several reasons why Kitron chose to automate with Element Logic, and one of them was that the industry […]

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Automation in production gives a competitive advantage

The investment in AutoStore has provided Kitron with satisfied employees, improved competitiveness, as well as more efficient production and distribution. The unique solution has been in operation for six years – with no downtime.

There were several reasons why Kitron chose to automate with Element Logic, and one of them was that the industry they operate in is very competitive and characterized by a lot of outsourcing abroad for cheaper labour.

Due to the ability and willingness to automate our processes, we are now in a situation where we are hiring more employees

Tone Helle, Production Planning Manager at Kitron.

“The fact that we are competitive means that we staff up, not down. The employees have been enthusiastic about automation from the very beginning and understand that it is necessary to be able to continue operating from Norway”, says Tone Helle, Production Planning Manager at Kitron.

COMPETITIVE: The AutoStore system contributes to increased profitability for Kitron to be able to operate from Norway.

Automated solution produces and distributes electronics.

Kitron is a contract manufacturer of electronics for the professional market. The history of the Norwegian company goes back to the 1960s in the Arendal area south of Norway. Since then, they have experienced several mergers and changes in the company. Until 2015, Kitron had two production sites in the Arendal area, but when the renting contract expired on one of the sites, they chose to move all operations to the remaining production site.

“This warehouse was too small for us and we had to optimize the warehouse solution to get enough space. After a couple of internal rounds of discussions, the natural choice naturally was AutoStore from Element Logic”, says Helle.

UNIQUE SOLUTION: The ability to put goods and components back in the bin dividers after use in an efficient way was unique and developed especially according to the needs of Kitron. As a result, this solution has been developed for several customers.

Developed tailor-made AutoStore solution.

The components Kitron uses to produce electronics are getting smaller and smaller in line with technological development. Kitron needed AutoStore to be able to efficiently retrieve small components for production and put the superfluous parts back in stock. The solution became a custom AutoStore system where some of the boxes are designed to be divided into as many as 30 locations.

“Kitron was our first customer in need of picking for production and returning the remaining parts in the storage bins. We designed a new solution with custom-built dividers in the bins that simplified the process and significantly reduced storage space. The effective solution picks between 2,000 and 2,500 transactions daily”, Arnold H. Nielsen, Key Account Manager at Element Logic Norway, explains.

We designed a new solution with custom-built dividers in the bins that simplified the process and significantly reduced storage space

Arnold H. Nielsen, Key Account Manager at Element Logic Norway.
Kitron production AutoStore Element Logic
UNIQUE SOLUTION: The ability to put goods and components back in the bin dividers after use in an efficient way was unique and developed especially according to the needs of Kitron. As a result, this solution has been developed for several customers.

“As this was the first time such an integration was carried out, it required some extra resources to get it in operation. As an AutoStore specialist, this gave us valuable insight that we have benefited from since”, Nielsen explains.

Want to read more about the whole process of AutoStore projects with Element Logic?

From 6300 to 7000 storage bins

Service technicians from Element Logic perform three regular service intervals a year at Kitron. In addition, Kitron can easily contact the experts in the support team whenever needed during the year.

“We experience that Element Logic responds quickly when challenges arise or when software upgrades are needed”, says Helle and adds:

“We are very pleased with the efficiency our AutoStore solution has given us, and we have not had downtime since starting six years ago.”

Kitron has increased the number of bins from 6,300 to 7,000 bins in recent years, but still has good opportunities for further expansions when the time is right.

“The best thing about AutoStore is that it is reliable, flexible, and easy to scale. As soon as the design is clarified, integration and installation go very smoothly”, Helle concludes.

Facts and figures:

  • Warehouse of 700 m2
  • 350 employees
  • 7 robots
  • AutoStore system of 187 m2
  • 7000 AutoStore bins
  • 1 Carousel ports
  • 2 Conveyor ports
  • Between 2000 og 2500 transactions picked daily from AutoStore

Want to learn more about our solutions?

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Achieved ROI on AutoStore in record time https://www.elementlogic.net/us/cases/achieved-roi-on-autostore-in-record-time/ Thu, 22 Aug 2024 13:21:39 +0000 https://www.elementlogic.net/?post_type=case&p=593 Elektroimportøren is a supplier of all electrical equipment for both B2B and B2C segments. With an enormous growth in recent […]

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Achieved ROI on AutoStore in record time

After only two years, the growing company, Elektroimportøren, achieved a return of investment (ROI) on its AutoStore system. Now, it is time to prepare for further growth.

Elektroimportøren is a supplier of all electrical equipment for both B2B and B2C segments. With an enormous growth in recent years, the turnover has gone from 20 million Euros in 2014, to 100 million Euros in the last twelve months.

With this impressive growth, it became clear that there was a need for a new warehouse, and to streamline the existing processes. Hence in 2017, the choice to automate was made, and already two years later, Elektroimportøren had a return of its AutoStore investment.

“We have been focusing on the cost, and not increasing it in line with our turnover”, says André Swensen, Logistics Director at Elektroimportøren.

Compact and smart warehousing

As Elektroimportøren had already decided to expand operations with a new warehouse, it became natural to involve Element Logic in the entire construction process to optimize for AutoStore.

People think you have to build a completely new warehouse to automate with AutoStore. However, this is only a myth, and we always find a solution that suits your building and your needs

Niklas Top Aanensen, Key Account Manager at Element Logic Norway

“People think you have to build a completely new warehouse to automate with AutoStore. However, this is only a myth, and we always find a solution that suits your building and your needs”, says Niklas Top Aanensen, Key Account Manager at Element Logic Norway.

It was a big decision for Elektroimportøren to automate its warehouse, but with thorough guidance from Element Logic, the process went quickly, and the result was above all expectations.

“It hurts a little when you hear the word automation in the logistics industry in terms of risk. However, now that we have become familiar with the robot system, it is clear that AutoStore primarily is a system for compact and smart storage”, says Swensen.

Expands the AutoStore system in 2020

The growth of Elektroimportøren does not seem to stop soon, and as a result, the decision to expand AutoStore further was made. The expansion consists of 9.600 bins, a picking tunnel, 4 port frames and 8 new robots. This is virtually twice the current system.

“Elektroimportøren is thinking ahead with the expansion of its AutoStore system. As it is today, there is still room for more bins, and the warehouse is thus well equipped for further growth”, says Aanensen.

The decision to expand for future growth came after thorough discussions with experts from Element Logic.

“Expanding AutoStore comes with costs, but by implementing a larger extension of the warehouse that provides space to grow, Elektroimportøren saves money and time on separate expenses such as electricians and installation”, says Aanensen.

EXPANDS: Elektroimportøren is preparing for further growth and is expanding its AutoStore system with 9.600 bins, a picking tunnel, 4 port frames and 8 new robots.

ROI and growth

When Elektroimportøren first invested in AutoStore in 2017, cost and ROI were top priorities. It was estimated that it would take between three to four years before the investment was returned, but in reality, it ended up taking only two years.

“During the planning of the extension with Elektroimportøren in 2020, ROI was not a topic any longer. It was unquestionable”, says Aanensen.

For other companies in a growth phase, the advice from Elektroimportøren is clear:

Take into account a possible expansoin. If you are a growth company, things go very fast and the key is to be prepared to handle it

André Swensen, Logistics Manager at Elektroimportøen

“Take into account a possible expansoin. If you are a growth company, things go very fast and the key is to be prepared to handle it”, says André Swensen, Logistics Manager at Elektroimportøen

Take a closer look at Elektroimportøren’s AutoStore solution in this video:

Facts and figures (after the extension):

  • A warehouse of 5600 m2 (18, 372 ft2)
  • 32 employees, 20 in the warehouse
  • 24 AutoStore robots
  • AutoStore of 750 m2 (2 460 ft2) including pick tunnel and service area
  • 20 350 AutoStore bins
  • 8 carousel ports for pick and putaway
  • 4500 order lines picked daily from AutoStore

Want to learn more about our solutions?

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A prime example of how warehouse automation takes logistics and e-commerce to the next level https://www.elementlogic.net/us/cases/a-prime-example-of-how-warehouse-automation-takes-logistics-and-e-commerce-to-the-next-level/ Thu, 22 Aug 2024 13:11:31 +0000 https://www.elementlogic.net/?post_type=case&p=556 “Our cooperation with Element Logic has been outstanding, and it’s only natural that we continue on this path together”, says […]

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A prime example of how warehouse automation takes logistics and e-commerce to the next level

The rapidly growing retailer Boozt sells 400 000 products to customers every month, and the number continues to increase. In order to keep up with the demands of the consumer they chose Element Logic as their system integrator for warehouse automation, with AutoStore.

“Our cooperation with Element Logic has been outstanding, and it’s only natural that we continue on this path together”, says COO in Boozt, Niels Hemmingsen.

Warehouse optimization for the future

The common goal of Boozt and Element Logic has been to enhance both companies’ competitiveness with the integration of warehouse logistics and e-commerce.

Boozt chose to implement AutoStore through Element Logic because of the practical benefits of the system, among others the possibility to integrate different systems, like ERP, WMS and WCS. The system can also be expanded on demand without shutting down ongoing operations.

Boozt's autostore grid
big food warehouse

Boost of efficiency

Boozt first installed an AutoStore system at their central warehouse in Ängelholm, Sweden in March 2017. Once the new AutoStore expansion is complete it will be the world’s largest AutoStore installation, featuring 500 robots and 500 000 bins.

“We’ve been operating our AutoStore since the end of March 2017, with very encouraging results. In order to keep up the good work, we’ll proceed with Element Logic in expanding our present AutoStore”, says Hemmingsen.

The integration with Boozt’s own WCS and ERP has proven to be a real booster for the online fashion distributor, improving workflow, customer satisfaction and delivery time.

Overall, the upgrade has reduced the need for storage space by a factor of four, thanks to AutoStore’s unique and compressed design.

An ever-growing business

In just seven years Boozt.com has traded for over 200 million Euros. They experienced further growth in 2018 when the warehouse was further expanded.

“Good support and dialogue are important when you automate. Our cooperation with Element Logic ensures that our robots work 24/7”, says Hemmingsen.

Facts and figures:

  • Installed in March 2017
  • 1 243 robots
  • 1 245 000 bins
  • 301 ports
  • AutoStore Router software (launched in 2020)
  • Robots running 24/7
  • Handles 400 000 products a month
  • Operational since 2017

Boost your efficiency

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A new logistics concept proved successful for TTI, Inc. https://www.elementlogic.net/us/cases/a-new-logistics-concept-proved-successful-for-tti-inc/ Thu, 22 Aug 2024 12:29:55 +0000 https://www.elementlogic.net/?post_type=case&p=487 TTI, Inc. was founded in 1971 in Fort Worth / Texas, USA, and expanded to Europe in 1992. Today, the […]

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A new logistics concept proved successful for TTI, Inc.

The global electronics distributor TTI has facilitated their day-to-day operations immensely by upgrading to Element Logic’s intralogistics solution.

TTI, Inc. was founded in 1971 in Fort Worth / Texas, USA, and expanded to Europe in 1992. Today, the company has more than 100 locations in Europe, North America and Asia. In its position as world market leader, space, energy and cost efficiency are essential success factors for TTI. However, storage space bottlenecks as well as long walking distances and processing times were a growing challenge in the original distribution center in Germany near Munich.

In 2018, TTI expanded its existing distribution center, building up a brand-new warehouse and investing in an automated storage and retrieval system. This AutoStore system – empowered by Element Logic – helped TTI to more than triple their storage volume.

About 100,000 different parts are always available in stock in TTI`s warehouse. Today, these parts can be stored in a way that requires less space, yet at the same time allows its employees to locate and pick them quickly and efficiently. With 40.000 order items per week and a promise to deliver almost all of its parts across Europe within 24 hours, the global electronics distributor secures its deliveries with the new intralogistics solution.

”With Element Logic we have an experienced partner at our side, who enables us to react flexibly to market developments in the future. Our AutoStore by Element Logic allows for optimal space utilization, increases the efficiency of the picking process and is the ideal system for us and our planned growth”, says Thomas Rolle, Vice President European Operations at TTI, Inc.

The company is already planning to further expand their system in cooperation with Element Logic. Afterwards TTI will have – at least temporarily – the world`s largest mezzanine-mounted AutoStore system.

“With our AutoStore system we do not only use the pure surface of the hall, but the entire volume”, Rolle explains. The core of the 3.800 m2 system is the bins that are directly stacked on top of each other on a 5,5 m high steel mezzanine. TTI`s system includes 16 bins in height, 82 bins next to each other in length and 119 bins in width – a masterpiece of engineering. Element Logic’s AutoStore system works on several floor levels, which allows a much better use of space. “Most warehouses are around 7-14 meters high, making them ideal for AutoStore systems. Usually, the inbound area needs only about two meters in height, leaving the rest of the space largely unused. However, since the AutoStore system is located on a 5.5-meter-high grid above the ground, this space is used in an excellent way”, Rolle continues.

Robots and humans working in tandem

This high-tech intralogistics system is structured very differently compared to conventional intralogistics systems. Notably, it consists of different levels, from the grid to the bin stacks and shafts, all the way down to the inbound area and picking stations. There are no shelves or paths in between, which saves a lot of space.

In fact, Element Logic’s AutoStore system saves an estimated 80% of the volume compared to classic, aisle-based systems. It works well for any small and medium sized parts.

tti-AutoStore-Swing-Ports-1024x683.jpg
INCOMING GOODS: Four automated Swing Ports handle all incoming goods into the AutoStore system without additional conveying systems.

On top of the 60 x 60-meter aluminum grid, 50 AutoStore robots are racing around with a speed of 3,1 meters per second. The robots are busy lifting up a total of 117.000 bins, restacking them and delivering goods to one of the 24 picking stations. The volume of AutoStore bins is about 22 percent larger than classic KLT boxes. They can also be equipped with dividers and you can choose between three different heights, depending on how much room you need for the various parts. The AutoStore bins are available in two different materials: HDPE and ESD.

Inside the picking tunnel, the TTI employees are equipped with highly ergonomic workstations that allow them to perform their tasks effectively and accurately. Additional Multi-Order-Picking equipment supported and guided by Put-to-Light solutions further improve the quality.

tti-AutoStore-Space-1024x683.jpg
SPACIOUS: The picking stations are located in the picking tunnel on mezzanine level. Coming down in a shaft, bins are presented to the workstations, where the items get picked in the blue target boxes.

The magic of the bins

The first question people often have when looking at the AutoStore system is: «What if the item you request is located in a bin that is buried at the bottom of a stack? »

“The robots need a maximum of 3 minutes and 24 seconds to dig out the bottom bin for a completely unplanned express order”, explains Michael Kawalier, Managing Director Sales at Element Logic Germany.

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BUSINESS PARTNERS: Thomas Rolle (left), Vice President European Operations at TTI and Michael Kawalier, Managing Director Sales at Element Logic Germany inside the new warehouse.

Part of the ingenuity behind Element Logic’s AutoStore solution is the software that organizes robots in two «swarms» and allows them to perform different tasks in parallel. One swarm is busy preparing the orders already received or just fed in, preparing the relevant bins that are needed next, and placing them in easy to reach top-level positions in the stack. The second swarm grabs these bins and delivers them to the picking stations. At the same time, other robots are busy delivering empty bins to the inbound stations and stowing the filled bins back into the grid. The robots can even organize bins outside of operating hours to have everything ready when TTI’s operators come to work.

“The AutoStore system optimizes itself during continuous operation. Frequently needed items automatically stay in upper regions of the grid. This is because the AutoStore operating principle always automatically puts the last required bin on top of the bin stack. As a result, rarely used C-items automatically sink lower and frequently needed A-items automatically remain in the upper regions. Thus, the access times become shorter over time”, explains Michael Kawalier, Managing Director Sales at Element Logic Germany.

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SWARM OF ROBOTS: TTI`s AutoStore system currently has 50 robots in use. These divide flexibly into «swarms»: one group prepares for the workstations, the second group prepares new incoming tasks.

For big and small warehouses

Element Logic’s AutoStore system is flexible, easily scalable, and it can be integrated with existing infrastructure. It can be implemented in small and large warehouses. The world’s largest AutoStore system (Boozt.com) to date was built by Element Logic in Ängelholm, Sweden. That facility has expanded to a capacity of more than 500.000 bins and 500 robots. According to Kawalier, Element Logic’s solution works perfectly for small warehouses too. The currently smallest AutoStore system has only 900 bins.

“AutoStore is represented in almost every industry. Everything that fits into these bins is stored in them: money, food, electronic parts, jewelry, mechanical components, spare parts, textiles, fashion articles, party supplies. Installing AutoStore makes sense almost everywhere if the items fit into the bins”, Kawalier concludes.

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A BRAND-NEW LOGISTICS CONCEPT: The AutoStore system was only one of the different scopes that Element Logic included in the overall solution.

Facts and figures:

  • TTI Inc., an international electronics distributor, part of the Berkshire-Hathaway Group
  • New warehouse with a size of 15.000 m2 in Maisach near Munich
  • 3.800 m2 footprint of AutoStore system by Element Logic
  • 40.000 order items per week
  • 50 AutoStore robots
  • 117.000 storage bins
  • 24 picking stations (carousel ports) with Multi-Order-Picking and Put-to-light equipment
  • 4 inbound stations (swing ports)

Could an automated storage and retrieval system be relevant for your business?

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Elektroskandia saved space, boosted warehouse efficiency and strengthened profitability https://www.elementlogic.net/us/cases/elektroskandia-saved-space-boosted-warehouse-efficiency-and-strengthened-profitability/ Thu, 22 Aug 2024 12:19:28 +0000 https://www.elementlogic.net/?post_type=case&p=383 In order to meet the demands of an increasingly competitive market, Elektroskandia Norge AS is dependent on efficient logistics. As […]

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Elektroskandia saved space, boosted warehouse efficiency and strengthened profitability

“With AutoStore® we can now store more goods in less space while simultaneously increase productivity”, says former Distribution Director, Arild Brennholm.

In order to meet the demands of an increasingly competitive market, Elektroskandia Norge AS is dependent on efficient logistics. As one of Norway’s leading suppliers of electrical equipment to the industry and installation markets, they are always focusing on improving logistics by using the most efficient storage & retrieval solutions.

Significant increase in efficiency with AutoStore®

In 2012, Elektroskandia chose to implement AutoStore®, empowered by Element Logic, in addition to the unique software Element WCS® – built to enable maximum performance of AutoStore®.

“AutoStore® made it possible to centralize over 60 percent of the goods and handling in one zone, which was earlier divided in several manual zones and vertical lifts and carousels. As a result of this, both the goods flow and efficiency were significantly improved but we were also able to reduce the number of shipments to our customers”, says former Distribution Director, Arild Brennholm.

With its unique trait as a space saver, AutoStore® enabled Elektroskandia to save as much as 1000 m² of floor space.

Retail Warehouse full of Shelves with Goods in Cardboard Boxes, Workers Scan and Sort Packages, Move Inventory with Pallet Trucks and Forklifts. Product Distribution Delivery Center.

Reduced costs and less impact on the environment

AutoStore® is a green line system that saves costs, due to state of the art technology, power-efficient modules and robots that regenerate batteries during operations, ensuring a low power consumption.

“The system also contributes to reduced picking errors and lower power consumption which, again, leads to reduced costs and less impact on the environment”, says Brennholm.

Element Logic as turnkey supplier

Faced with increased activity on project deliveries, Elektroskandia decided to establish a new DC to get the necessary flexibility and efficiency needed in the future.

For the new 14 500 m² building that was opened in 2017 in Langhus, outside of Oslo, Element Logic was the turnkey supplier – providing Elektroskandia with all the warehouse equipment, including pallet racking, cable drum racking, cantilever racking, as well as moving and somewhat increasing the AutoStore system.

“Together with Element Logic, we put a lot of effort in making the warehouse as functional and efficient as possible, avoiding complexity and emphasizing flexibility,” says Brennholm.

The move of 222 semi-loads of goods, including the AutoStore system, was a big challenge that required a lot of planning in cooperation with Element Logic.

“We are very satisfied with having executed this project while maintaining full operations, without any customer complaints or problems,” Brennholm concludes.

Boost your efficiency

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