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Wuppermann has been one of the leading companies in the processing and finishing of steel for 150 years.
In recent decades, Wuppermann has developed from a steel processor to an innovation leader in corrosion protection through the heat-to-coat hot-dip galvanizing process. Wuppermann AG has a total of five production sites in Europe.
At the Moerdijk (NL) and Gönyű (HU) sites, we were commissioned with an all-in-one solution for the modernization and expansion of the existing warehouse and production logistics.
On the one hand, this extensive retrofit included the control and management of the entire material flow, from the booking of raw materials at goods receipt to the supply of the production facilities and the shipping process.
On the other hand, the ABF solution also replaced and improved the management of forwarders, from registration at the entrance gate to the factory premises, to automated assignment to the correct loading bay and loading management with integrated photographic documentation of loading security.
To manage the existing automatic crane stores, the automatic cranes and coil trolleys were controlled using our software solution OneBase®MFT.
The interfaces to the existing hardware and system landscape could be integrated into the ABF solution without any changes.
The now direct connection to the SAP ERP system improves the efficiency of communication between the systems compared to the old system.
For material tracking in the areas of the plant served by manual forklifts and cranes, the mobile application OneBase®MFT Cockpit mobile application is used.
The improved visualization of the warehouse stock thanks to the 3D visualization and the additional fully configurable list display, which can be adapted to the customer’s requirements, shows all the information relevant to the respective operator at a glance and thus further contributes to increasing intralogistics efficiency.
The revised loading processes were implemented in the new ABF shipping solution in close cooperation with the customer.
The OneBase®MFT Cockpit solution automatically guides the operator through the entire loading process and offers integrated documentation of the loading security.
A handheld application enables trimodal loading onto ships, trains, containers and trucks with loading processes adapted to the means of transport.
The ABF shipping solution was also connected to existing system interfaces of the existing systems.
A new tendering solution was introduced at the customer during the project.
The additional data provided was integrated both into the access restriction at the gate and into the automatic loading bay assignment of the trucks.
A solution with automatic license plate recognition and improved, rule-based access restriction as well as control of the entry gate was implemented at the entrance gate to the factory premises.
Thanks to the automated linking of the license plate with the transport document and the efficient and guided control of the shipping process in the handheld application, the shipping process up to the printing of the loading documents can now be handled completely paperless and efficiently.
The new loading management component in the ABF system assigns trucks to the correct loading bay based on rules.
The set of rules used was adapted in close cooperation with the customer so that the specific requirements for each loading bay and type of transport are correctly assessed.
The use of a handheld that can now be used universally in all production and shipping processes reduces the number of applications and hardware (different handhelds) to a single system.
This handheld is used to manage both the raw materials identified by RFID tags in the outdoor area and the finished goods identified by barcodes in the indoor area.
The use of just one type of handheld enables simpler spare parts management and faster training.
Every process step was implemented in digital form with this intralogistics retrofit.
The ABF solution not only saves paper, but also achieves a considerable increase in efficiency by avoiding errors.
The project was implemented within a project duration of one year.
The old system was replaced by the ABF solution in separate multi-phase start-ups in the individual areas of the automatic storage system, belt cutting system, dispatch area and automatic storage system for raw materials.
The commissioning could thus be carried out in full operation without any downtime of the production line caused by the ABF system.
