From entering an order to having that part ready to ship in 15 minutes. That’s just one of the many advantages of TVH’s new automated warehouse in Waregem, Belgium. And that's a clear win for the customer, because fast logistics = fast delivery!
Automation is a game-changer in logistics. With cutting-edge technology, it reduces handling, avoids errors, and guarantees 24/7 performance.
TVH designed its new warehouse with in-house knowledge and experts in the field like TGW and B+ Equipment (now part of Sealed Air). A partnership that made us unstoppable in exploring the project’s full potential.
Optimising the flow
“The first hurdle we tackled was optimising the flow of goods,” explains Bart Reyntjens (Automation Engineering Architect, TVH). “We wanted to avoid all unnecessary handling that could slow down the process or lead to mistakes.”
To achieve this, TVH’s design team conceived a unique 1-2-1 sequential picking system. “All the totes with the right parts are picked automatically from the shuttleblock ASRS (Automated Storage and Retrieval System). These boxes are then presented in the right sequence and at the right location to the picker,” he continues. “The only remaining manual operation is filling the cardboard box for the customer.”
TVH’s automated packaging process allows us to use up to five cardboard box sizes. These different sizes offer maximum flexibility and avoid unnecessary large packaging for smaller parts.
- The machine automatically folds the cardboard to the right box size, ensuring optimal space usage.
- Once the parts are in the box, the paperwork follows automatically and a camera checks the contents.
- When the box is closed, we register the weight.
- The Print & Apply machine attaches the labels before sending it off to be stacked on the right pallet.
Performance around the clock
To guarantee productivity at all times, we had to create advanced redundancy. That means we can still operate at a high capacity, even when segments of the fully automated system are down. We made this possible with alternative conveyor routes, double lift connections to the ASRS, redundant closing machines and other backup systems. Even in the unlikely event of a major failure, our automated process is back up in no time thanks to a swift recovery process.
In-house design and joint execution
TVH’s WB3 warehouse isn’t an off-the-shelf solution. “We took the lead in the design process and collaborated with industry specialists, such as TGW for the storage and conveyor belts, B+ Equipment for the automated packaging and Fraxinus for the stacking mechanisms,” Bart explains. “All WCS (Warehouse Control System) programming happened in-house, and we are fully in charge of the upkeep and maintenance of the entire system.”
Automation is the future of sustainable logistics. “This new warehouse gives us a competitive advantage,” he concludes. “It allows us to be more productive and get parts quicker to the customer.”