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In the Eger factory of ZF Hungária Kft., they manufacture manual and automated gearboxes and their parts. The company has been present in Hungary for nearly 25 years. Their customers install them in trucks, buses, small commercial vehicles and cars. In the fall of 2018, the production of automatic transmissions also began at the company’s site in Eger.

To manage the constantly growing amount of material, they chose an error-free, automated warehouse solution. The turnover of goods is about 1000 – 1200 pallets per day. Two types of automated warehouses were created to store the raw materials and from there to serve the production lines: palletized goods are stored in a system with a capacity of 7,800 pallets, and piece goods are stored in a system with a storage capacity of 25,056 storage boxes. Jungheinrich was entrusted with the design and construction of the automated warehouses.

The handling, storage and transfer of goods to production is supported by Jungheinrich’s various tools and solutions. The warehouse operates in three shifts. Automated solutions also helped to optimize the workforce.

Four years ago, as part of a large-scale investment, a 40,000 m2 hall was installed as a first step, which housed an automated high-rise warehouse and a completely new assembly line on which the 8-speed automatic transmissions are manufactured.

Thanks to the dynamic growth, the management of the constantly increasing amount of material could only be solved with an error-free, automated warehouse solution. Two types of automated warehouses were created to store the raw materials and to serve the production lines.

“We asked Jungheinrich to design and build the automated warehouses. Jungheinrich already convinced us with his competent, professional advice during the proposal phase, when developing the material flow concept and the layout. The company provided the best concept in terms of efficiency, space utilization and reliability at a competitive price,” he said Stefan Baumeister, managing director of ZF Hungária Kft.

Jungheinrich started building the automated high-rise warehouse in January 2018, and everything was operational in August. “For the volume we want to produce in this new hall, an automated warehouse solution was the only economically viable option. In the warehouse, we have to solve the movement of parts necessary for nearly 360,000 finished products per year, and we can only handle this quantity in an automated way, since otherwise we would have to employ very significant human resources,” the specialist continued.

“When choosing the system supplier, the most important thing for us was that the operation and maintenance of the automated system was concentrated in one hand, which is optimal from a cost-effectiveness point of view, since the technical support and the continuous system monitoring are solved here in Hungary.”

In the goods receipt area of ​​the warehouse, pallets and CTLs are entered in the SAP system. It is separate whether the given transport unit is stored in the pallet or the KLT warehouse. A self-supporting, 4-aisle, 21 m high high-rise warehouse with a transport system was created for palletized goods, where 3 storage points were created, each of which has empty plastic carrier pallets prepared. The operators place the incoming, different types of rolls with the goods on the standardized pallets, and then the pallets are automatically stored and registered in the warehouse. The picking process is initiated via SAP by the demand for goods generated in production, and this is immediately displayed in the Jungheinrich WMS system, which automatically starts the picking of the pallet for which the demand was generated from the company management system based on the FIFO principle. When this pallet reaches a certain point on the conveyor, it receives a kanban tag there. 3 automatic label printers were installed on the conveyor to print kanban labels.

At the 6 pick-up points on the track, the pallets are lifted with a forklift, and the materials are delivered to the production lines using the milkrun system. The connection of the automatic warehouse with pallets to the goods receipt and delivery area was solved with a conveyor system on two levels. There are two options for storing the incoming CLT items in the warehouse: either they are placed on a pallet onto a depalletizing robot, which removes the CLTs from the pallet and places them on the conveyor, so they are automatically stored, or the crates can be placed manually, one by one, on the conveyor, and that’s how they end up in the two-aisle, 7.5 m high automated warehouse. The picking process from the small parts warehouse starts in the same way from production, and then, based on the information transmitted from the WMS, the loading machines pick out the required crates. A redundant section with two cranes has been created here so that production can be supplied in any case. The crates are automatically picked up for production. During pick-up, the crates are provided with the kanban label corresponding to the production by the printers installed near the track, on which the number of the rack next to the production is indicated. Jungheinrich software, the Warehouse Management System and the Warehouse Control System, are used for both automated warehouses, which are connected to the company management system of the Eger factory via an interface.

Related to this topic, we recommend our article about PowerCube, an automated compact storage system.

Source: technokrata by

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