MAHLE Aftermarket recently implemented an AutoStore automated storage and retrieval system, or ASRS. It used a Kardex robotic cube storage system to increase capacity and throughput.
Before implementing the AutoStore system, MAHLE was experiencing storage capacity constraints at its distribution center in Olive Branch, Miss. The global parts and systems provider looked for high-density storage that would help it adapt to the shift in customer order profiles and that would be scalable for future growth.
MAHLE evaluated a range of options before choosing the AutoStore system powered by Kardex. Kardex deployed an AutoStore ASRS specifically tailored to MAHLE’s material flow, with high storage density and processing.
“One of the reasons we chose Kardex is because, compared to the other integrators, they were able to provide an end-to-end solution tailored to our material flow, whereas the others were focused on selling their solution and not a holistic approach,” stated Lorraine Hinderer, head of business innovation and excellence at MAHLE.
“I would recommend Kardex to other companies — and have, actually — just due to the way that they support in the whole initial design and sizing… but also in actually implementing the system on-site.”
MAHLE said AutoStore’s system will allow it to better handle more small-package orders and less-frequent, large-stock pallet orders.
AutoStore, Kardex move 42k bins
The complete AutoStore system at the Mississippi facility includes 42,000 bins, seven ports, and 18 robots, in addition to a connected conveyor with 18 gravity lanes used for consolidation.
Designed by the experts at Kardex, the ASRS was commissioned on schedule and ramped up quickly and smoothly, the companies said.
“The support provided by Kardex exceeded expectations,” said Rhiannon Fisher, head of business excellence for the North America region at MAHLE Aftermarket.
“During the design process they were very hands-on,” she added. “They provided support on-site during the entire process and ultimately delivered a turnkey solution.”
MAHLE sees a four-time increase in capacity
Kardex FulfillX maximized the capabilities of AutoStore’ cube storage to optimize resources and processes. It increased capacity by up to four times and enhanced performance by up to 10 times compared with traditional methods. The system did this without requiring an additional workforce, the partners said.
Fred Fox, director of project success for the Kardex Solutions AutoStore team, explained that clients can use the Kardex FulfillX software designed specifically for AutoStore. Alternatively, they could integrate other warehouse management systems (WMS) or use their own software.
MAHLE Aftermarket chose to integrate with its existing SAP WMS.
“Together, we got a really good solution in place and that’s just part of who we are and what we want to do,” Fox said.
Following the success of the Olive Branch project, MAHLE Aftermarket automated a second operation in Décines-Charpieu near Lyon, France. This deployment included 22,440 storage bins, seven robots, and two workstations.
MAHLE said it is evaluating other locations worldwide to assess if AutoStore empowered by Kardex can enhance customer service, increase efficiencies, and standardize its operations.