The national logistics centre in Neu-Isenburg is part of an extensive initiative by the REWE Group, which aims to ensure a faster, more efficient, and high-quality supply of goods for REWE store customers in the long term by optimizing the warehouse network.
As part of this initiative, the logistics centre is being equipped with innovative technology. In this regard, the food retailer has chosen to work with the WITRON Group to implement the fully automated OPM system. In the future, the logistics centre in Neu-Isenburg will supply 2200 stores with 16,700 different dry goods and pick more than 640,000 cases on a peak day.
“REWE and WITRON have delivered a masterpiece with the realization of the logistics centre in Henstedt-Ulzburg (Germany)”, stated REWE Logistics Manager Lars Siebel. “And we want to replicate this success in Neu-Isenburg.”
Brownfield project
As part of a comprehensive re-organization initiative, a semi-automated Case Picking System with aisle-bound picking cranes will be replaced by a fully automated Order Picking Machinery (OPM). The end-to-end integration of the new solution into the already existing material flow infrastructure takes place during ongoing operations.
From Q3/2027, 22 COM machines will stack 247,500 cases daily onto pallets and roll containers in a store-friendly and error-free manner. A tray warehouse including 167,900 storage locations and 48 stacker cranes is located upstream. Replenishment is sourced from an existing automated pallet warehouse with 65,500 storage locations, which will be expanded by two additional aisles, adding to a total of 9,500 storage locations.
More items, more throughput
“OPM’s key benefit for REWE is its ability to ergonomically store and pick over 100 percent more case picking items in the future, achieving a 20 percent higher total throughput at the site. While the previous solution encompassed 3,000 different items, OPM now encompasses 7,8000 items. The pick performance will increase to 247,500 picks per day”, explains WITRON Project Manager Markus Lang (pictured).
Markus Lang
“In addition, the OPM integration ensures efficient consolidation with piece picking orders from the WITRON DPS and OPS tote picking systems, as well as with large-volume items / bulky parts from the WITRON CPS system.” Both the DPS and CPS have been successfully in use in Neu-Isenburg since 2014. The OPS was put into operation in mid-2021.
Lifetime Partner
As a lifetime partner, WITRON is responsible for the design, implementation, and the on-site service of the extensive logistics expansion in Neu-Isenburg. All IT, PLC, and mechanical components are developed at WITRON’s headquarters in Parkstein. In addition to the material flow design, WITRON was also involved in the conception of the transition strategy, which outlines the seamless supply of the stores during the restructuring phase. WITRON also supported the selection of a reliable recycling partner who would take care of the professional dismantling and disposal of the logistics technology that would no longer be used in the future.
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