1500
Rail meters
3
Floor conveyor
ERROR-FREE PICKING OF COVERS (JIS)
JUST-IN-SEQUENCE (JIS) DELIVERY OF COVERS
MATERIAL-FRIENDLY HANGING STORAGE AND TRANSPORT
PERMANENT INVENTORY CONTROL
SIGNIFICANTLY LOWER OPERATING COSTS
ERGONOMIC WORKSTATIONS
PLANT FLEXIBLY EXPANDABLE
OPTIMAL USE OF SPACE
THE GOAL: RELIABLE PROCESSES FOR JUST-IN-SEQUENCE PRODUCTION (JIS)
Faurecia manufactures vehicle seats at the Neuburg a. d. Donau site for the Audi A4 model. At Audi in Ingolstadt, up to 1,700 vehicles per day are being equipped with these seats. That means more than one set of seats per minute has to leave the Faurecia plant. In order to optimize the work processes in view of the very short lead times, the automotive supplier has relied onthe fully automated Schönenberger IntraLogistics System ILS 2100 since 2017.
Audi A4 customers can choose from different types of leather and fabric, colors and stitching for the seat covers – in combination, around 900 variants are thus possible. Pre-production is not possible due to this diversity. Faurecia produces the seats therefore only immediately after call-off (just in sequence).
In total, there are only eight hours from receipt of the order to installation at Audi, including transport times .
SCHÖNENBERGER
ILS 2100: FOR THE SEQUENCING OF A HIGH PART VARIANCE WITHIN SHORT TIME
Before the fully automatic ILS system was introduced, employees had to manually search for the required seat covers in the warehouse and bring them to the various production stations. With short lead times, last-minute changes and call-off orders every few minutes for around 16,000 seat covers in the warehouse, this was a difficult task. Today, filtering, sequencing and transport to the workstation are carried out automatically by the system, which covers all areas of reference production at the Neuburg site: from incoming goods to dynamic storage and sorting to the workstations. Storage and sorting carousels allow quick access to every item in the system.
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FULLY AUTOMATIC TRANSPORT, RESPONSIVE PROCESSING
With the ILS 2100 intra-logistics system, Faurecia opted for a high-performance, highly flexible system for storing, picking and sequencing individual items. First, each seat cover is clamped at goods receipt, the product code is scanned and “married” with the barcode of the single carrier trolley. The covers are automatically transported to the warehouse under the hall roof. Here, the covers are distributed in dynamic storage blocks to different storage sections. This storage of goods may seem chaotic at first glance. In fact, however, this increases the hit rate, since parallel searches are performed in all storage blocks. The selected covers are transported to the sorter, where they are brought into the correct sequence and temporarily stored in a buffer area. They finally reach the mezzanine floor via floor conveyors, are automatically unloaded from the single-carrier trolley and then delivered just in sequence to the respective assembly station via a pin conveyor.
NO SPACE CONSUMPTION THANKS TO SUSPENDED TRANSPORT AND STORAGE
The ILS 2100 system has been in operation at Faurecia in Neuburg since September 2017. The intended optimization and cost effects quickly became apparent. Warehousing, picking, sequencing and delivery are managed by only one employee per shift. The room height and the available space are optimally utilized: The warehouse, sorter and buffer were built two stories up. The goods are transported up and back down via steep floor conveyors. The delivery of the covers to the workstations also takes place above the heads of the employees. This frees up valuable floor space. The new plant was built during ongoing operations without any significant disruptions. Its mechanics prove to be robust and low-maintenance; minor errors are remedied in no time. Ergonomic workstations support and relieve employees. Thanks to consistent tracking of all items in the system, inventory management is always up to date. For quality checks, individual covers can be requested and checked. The error rate today is close to zero.
Customer testimonials
“Every failure of the system is an emergency – because then production also stops quickly at our customer. Since commissioning the Schönenberger system, we have not had to activate our emergency concept once.”
Stefan Tilli, Project Manager and UAP Manager at the Neuburg on Danube site
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