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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