 In the new Storopack Logistics Centre in Esslingen, Germany, Crown reach trucks play a key role in the just-in-time despatch and delivery of service literature to all the DaimlerChrysler plants, subsidiaries and contracted sites throughout the world.
Storopack (a family owned packaging manufacturer with 70 subsidiaries worldwide) decided to relocate its distribution and logistics activities for DaimlerChrysler - carried out by Star Distribution GmbH - from its head office in Metzingen to Esslingen just over two years ago.
Over an area of 15.000 sq m up to 60 staff of Star Distribution are involved with storing, picking, packaging and posting manuals, operating instructions, maintenance sheets, brochures, price lists, posters etc.
"No new car can leave the manufacturer without a manual and operating instructions" explains Achim Janoff, manager of the Esslingen site. "That's why we need to deliver on time, reliably and with minimum error."
"Punctuality is the golden rule, which is all the more reason for choosing solid and reliable partners, such as Crown Lift Trucks," he continues," whose service engineers are with us within 15 minutes at the most should the need arise."
Currently the site operates 14 Crown trucks under a full service contract. In the event of increased capacity requirement the Crown rental fleet is used, as was the case during the company's relocation. "The rental trucks ensure we remain flexible and also mean that we can react quickly at any time to any customer special operations," explains Achim Janoff.
Seamless Distribution Chain
Internal transportation and storage processes at Storopack start with the unloading of incoming lorries direct from a number of printers in the Stuttgart area who supply a wide range of service literature in up to 24 different languages on pallets. Crown WP 2000 electric pedestrian pallet trucks are used to transport the goods from the lorry to the goods inward area. The trucks feature an ergonomic control handle that can be held with a minimum of effort during the transportation process.
Incoming pallets are then stored in the high rack warehouse by ESR 4000 reach trucks or using SP 3000 stockpickers. Some 18,000 items are stored in the high rack warehouse for between on average one and six months. Currently 8000 of the 9030 pallet spaces are occupied. The highest rack level is 10.30m and is used solely for pallet storage.
Camera and Colour Screen
For operator ease and productivity in the handling of up to 250 pallets a day the ESR 4000 reach trucks are fitted with a camera - located on the inside of the forks - and a cab-mounted colour monitor which provides a clear view for the drivers with regard to positioning the forks when entering pallets at height. It also safeguards against damage.
The ESR trucks - offering faster lift and travel speeds when compared with competitive trucks - are additionally fitted with a lift height pre-selection system and a weight display, which helps to further accelerate the storage and handling process.
On Board Remote Control
To make full use of the existing space, Storopack also uses a 12m high mobile rack system. The 75m long and 30m deep rack is divided into three storage blocks - whole pallets for JIT site deliveries, supplies for the picking warehouse and marketing documentation in the final section.
All zones are enclosed by static racking, with six mobile storage racks operating in between - each with a maximum capacity of 300 tonne. In each block a 5.40m wide aisle can be opened up to allow three trucks to work at the same time. During stocktaking three 1.80m aisles open up in each block to allow lifting platforms to be used.
All entrances, exits and even the aisles themselves are monitored by an access light barrier system. On board the reach trucks and stockpickers is a remote control system to provide automatic opening and closing. With this system the driver can open the aisle for the next storage and retrieval operation, even when travelling, without dismounting from his truck.
Optimised Processes
When the goods have been stored they are booked into the stores management system. Retrievals from the mobile rack system are carried out by Crown SP 3000 Stockpickers. These one tonne capacity machines, with lift heights up to 7.770m, feature a sturdy lift frame that ensures minimal cabin movement at maximum height. Moreover the driver can only be raised when the side doors are closed, the foot pedal is pressed and the safety lever applied with the left hand.
Some 300 to 400 deliveries leave Esslingen each day, and given these throughput levels, says Achim Janoff, "a supportive seat position is absolutely essential for forklift drivers. That's why we let our drivers test trucks from various manufacturers before deciding on Crown, who matched our requirements best of all when it came to ergonomics and service."
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