Pioneering achievement in energy-efficient manufacturing
The material flow in the NExT Factory starts in the inbound area, where the materials are identified and sorted, followed by automatic depalletizing. The ARCs transport the sorted material just-in-time to the automated storage and retrieval system (ASRS), which has 43,000 storage locations on 32 levels. A central element is the energy recovery system: the integrated direct current (DC) network with recuperation technology stores up to 90 percent of the energy released when the ARCs move to a lower level in the ASRS in order to increase energy efficiency.
The ARCs distribute the materials to the respective production areas and ensure that the stations are supplied on time. For transport to sensitive areas, such as the clean room, the materials pass through special gates and doors: high-speed gates that prevent contamination, and fire doors that ensure safety in an emergency.
Warehouse management is carried out centrally via SAP EWM, which closely monitors the flow of materials. The Servus software coordinates transport tasks and optimizes the use of the ARCs. Along the routes, buffer locations serve as temporary storage buffers to prevent bottlenecks and ensure continuous production.
Initial situation
Use of a DC grid (the world's first direct current powered factory)
Objective: Reduction of energy costs by 15%
Requirement for temporary storage locations to avoid bottlenecks
customer benefit
Improving sustainability and carbon footprint
Cost savings through efficient warehouse and production logistics
Ensuring a smooth flow of materials and avoiding bottlenecks
We have implemented one of the most innovative energy concepts in the building. Throughout the project, Servus proved to be a competent partner open to questions and suggestions.
Rainer Pitz, Director Operations Schaltbaus
Schaltbau, Velden (Germany)
Schaltbau Velden specializes in the development and manufacture of highly reliable safety technology for rail transport. The company produces contactors, relays, switching devices, and electromechanical components that are used in railway systems worldwide to ensure safety and smooth operation in rail transport.
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