Our order numbers have been rising while batch sizes have been shrinking
reason , we have continuously expanded our capacity in this area . It has led to increasing customisation . Our order numbers have been rising while batch sizes have been shrinking . This , of course , poses a major challenge for us in manufacturing and logistics .”
Weser Stahl relies on modern machinery and equipment to meet this challenge . It has several bandsaws and circular saws supplied over many years by KASTO . “ We particularly appreciate this supplier ’ s ability to provide solutions , even when we have special requirements ,” Dr . Krummenerl added .
This was a key reason behind its decision to engage KASTO , a sawing and storage equipment manufacturer . Weser Stahl decided to launch an ambitious project to automate the provisioning of the saws to run largely unattended . This would enable it to handle the increasing numbers of orders and meet the growing customer demand for partfinished products .
Dr Krummenerl continued , “ Another important aspect for us was safety in the working environment . We wanted to make our employees ’ activities more ergonomic and their daily tasks easier , to prevent accidents and injuries .”
An eye on storage
Previously , material had been transferred to the saws by an overhead crane – a laborious and not entirely hazard-free procedure involving bars and tubes weighing a tonne or more . After detailed calculations , KASTO determined that the system to replace this process would be a fully automatic , cantileverarm storage system .
Weser Stahl opted for a KASTOcenter varioplus 4 . Measuring almost eight metres in height , the system provides 1,398 storage spaces for material of up to seven metres in length . The compartments have a usable loading height of 50 to 430mm and each can take a maximum of four tonnes of material . Stock is handled by a storage and retrieval machine ( SRM ) that moves at speeds of up to 60m / min . Two KASTOvariospeed circular saws , also automatic , and one KASTOtec bandsaw are connected to the storage facility .
The stockholder holds about 20 per cent of its inventory in the storage system . Sales manager , Stieven Harder , explained , “ We know what kinds of pre-cut parts are most frequently requested and we give preference in storage to these materials .”
Stock is usually delivered by truck in bundles that are unloaded , unpacked and
placed in storage via a transport cart . Selection of a suitable storage location is handled by the KASTOlogic warehouse management system , which optimises SRM travel to minimise access times . Mr . Harder further advised that , to protect against rust , there are separate storage areas for bright steel and rolled steel and the rules for this segregation are also contained in the software . The KASTOlogic is connected via a special interface to Weser Stahl ’ s higher-level ERP system , ensuring greater transparency and simplifying the communication of order data .
Material removed from storage is conveyed via roller tracks to whichever saw has been assigned to fulfil the job . A handover station in front of the saw serves as an additional buffer to avoid waiting times . The two KASTOvariospeed circular saws each have a cutting capacity of up to 150mm , while the KASTOtec FC 4 bandsaw is suitable for larger material up to 430mm in diameter . The latter saw was in use before the storage system was built . Kasto simply integrated it into the new system and added the two circular saws .
Continuous material flow
Weser Stahl also relies on automation for the removal of material . The KASTOtec saw is equipped with a turning and stacking system and the two KASTOvariospeed saws each have an industrial robot that automatically removes sawn sections and stacks them onto pallets , as required for each order . The automated peripheral systems including robot integration were also implemented by KASTO . Mechanically , electrically and in terms of software they are matched to the automatic sawing machines and storage system .
Harder stated : “ In this way , we have created a continuous material flow that can function fully unattended , if necessary – and around the clock . The result is an enormous increase in efficiency and performance , as well as more ergonomic working conditions for our employees .”
Remnants are returned to storage by the conveyer system and SRM . The latter has been specially reconfigured so that it can carry several pieces at a time .
Weser Stahl and KASTO have further plans for automation . They intend to introduce a Jungheinrich driverless transport system to connect the saws and remove pallets with stacked cut parts from the working area of the KASTOsort robot and take them to the dispatch warehouse . KASTO has already created the necessary peripheral equipment , such as the protective enclosures for the saws with a roller gate and optical sensors for entry and exit by the automated guided vehicles . n
STORAGE AND STACKING
Stock is handled by a storage and retrieval machine ( SRM ) that moves around the store at speeds of up to 60m / min .
Two KASTOvariospeed circular saws are connected to the storage facility . KASTOsort robots handle sawn sections .
The bandsaw is equipped with a turning and stacking system for material removal .
An existing KASTOtec FC 4 bandsaw was integrated into the new system .
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