Download Modine (Germany) - Copa-Data

logistics
I hörmann at modine
Streamlined, sequenced
production without stock.
In its conveyor and storage system from Modine, Hörmann Logistik has implemented a production concept that gives customers the ability to manufacture
their products in a streamlined, sequenced manner. This has enabled Modine to
reduce its stock of finished goods considerably. zenon from COPA-DATA is responsible for the visualisation and efficient operation of the conveyor processes.
❘❙❚ Modine’s innovations have set stand-
assembly plant operated by the company
transparency in the production process
ards throughout the industry for efficien-
that leads the way in the international
as well as traceability of each individual
cy, cost effectiveness and long service life
cooling and heating systems market. Mo-
product. Modine’s aim is to achieve flex-
in the field of heat transfer. The company
dine produces cooling systems for the au-
ibility despite fluctuations in capacity,
has been in existence for over 90 years,
tomotive industry, most of which are used
because 100 percent reliability in produc-
and has registered more than 2,000 pat-
within the BMW Group. Modine products
tion and delivery must be ensured at all
ents. It is now in the best possible posi-
are well known for reliability. In order to
times.
tion for overcoming challenges now and
keep up with the ever-growing volume of
in the future in the area of heat transfer.
orders and the high demand for product
To get the solutions to market reliably and
diversity, the company got together with
quickly calls for just-in-time and just-in-
Hörmann Logistik to redesign the entire
maximum degree
of automation and
efficiency
sequence production and logistics proc-
production and materials handling opera-
The plant in Wackersdorf is now struc-
esses. The internal logistics must function
tions and build a new plant in which to
tured and implemented using a sophis-
practically, reliably and economically.
set up these operations. Needless to say,
ticated intralogistics solution from Hör-
the aim was to satisfy the requirements
mann Logistik. HiLIS, the intralogistics
of their customers, and to supply them
system from Hörmann, manages all the
with products just-in-time and just-in-
storage and buffer areas, controls order
sequence. The aim was to ensure total
picking, and with its “Factory Control”
reliable supply of products to the bmw group
Modine
Wackersdorf
GmbH
is
an
hörmann at modine
I logistics
inspection stations and quality assurance.
The inspected coolers then pass into a sequencing buffer, where they can be made
available in the order requested by the
car manufacturer. At all times, throughout the entire storage and assembly processes, the cooler data can be accessed.
13 programmable logic controllers (S7),
linked together via TCP/IP, are deployed.
Approx. 22,000 values are read and processed in zenon. Transponders pass the
information on to the suspended electric
trains, and barcodes ensure that the data
exchanged at the load suspension devices
is correct.
module, takes control of the entire pro-
the intralogistics plant in real time. The
zenon ensures that
monitoring is carried
out comprehensively
duction process. HiLIS thereby ensures
ergonomic, graphic display in zenon as-
At Modine, zenon also provides a com-
maximum transparency and plant avail-
sists the user with simple working dialog
prehensive system monitoring module.
ability in all functional areas. Using the
boxes. zenon is set up as a multi-station
Users and Maintenance Engineers can
‘target goods out date’ and ‘sequence
system, and at each station it provides a
rapidly diagnose and rectify potential
chain’ parameters, the whole plant is
comprehensive overview of the plant and
system faults because they can access all
controlled in such a way that all the cool-
the states occurring within the plant. The
the information directly. zenon flags up
ing systems are shipped just-in-time and
software supplies all the detailed data at
any errors that arise, and records them in
just-in-sequence. The programmable logic
each conveyor device (storage/retrieval
a central error-logging module. The statis-
controllers (PLCs) supply the informa-
device, cross-carrier, suspended electric
tics not only permit detailed fault analy-
tion for controlling the storage/retrieval
train) and at each storage location, be
sis, but also enable trends to be analysed
equipment and conveyor systems. The
that in a grid system, pallet conveyor sys-
in the long term. All these systems can
HiLIS Warehouse Management System
tem, in workpiece carriers or a high-bay
also be maintained from a remote location
module is responsible for managing stor-
warehouse. Altogether there are seven
via a VPN (Virtual Private Network). Any
age, stocktaking and order handling.
operator stations (server, redundant
information that is generated and record-
Materials flow control coordinates and
server, web server pro with five licences).
ed in the course of the logistics processes
optimises all the manual and automatic
The operators and maintenance engineers
can also be exported if required. Thanks
storage, conveying and transportation
can therefore, thanks to zenon, always
to the flexible interfaces – in this instance
systems. The flow of goods can be ad-
see and understand which lattice box or
to the SAP software – HiLIS can be linked
justed and customised in each functional
pallet container contains which individual
up with existing ERP systems. Mobile
area according to the operational require-
components for the coolers, or where they
devices like PDAs and tablet PCs with
ments. An international transport order
are located in the high-bay warehouse.
touch screens can also always be reliably
can be broken down into partial orders
zenon also clearly displays the convey-
connected via the wireless LAN. A plant
for each specific plant. zenon forms a part
ing processes involved in moving cooler
operator or the maintenance engineer
of this solution.
components to where they will be further
will be provided with electric vehicles
processed. From the high-bay warehouse
with integrated mobile computers. If, for
the cooler components are moved to the
instance, fault messages occur, then the
workers’ stations using suspended elec-
relevant employee can respond quickly
COPA-DATA’s zenon software is respon-
tric overhead conveyor in order that they
and directly. Thanks to zenon, faults can
sible for the plant visualisation at Mod-
can be further processed on the work-
be displayed directly on the monitor and
ine, depicting all the functional areas of
piece carriers and then moved on to the
rectified using the touch screen. ❚❙❘
intralogistics with
zenon