Warehouse production goes fully automated

Our material handling customer’s current consumer goods warehouse production process was running at full capacity. With throughput set to increase by an additional 3,000 incoming containers per hour and 2,500 outgoing packages, they needed to expand their warehouse operations.

We had to install a modern fully automated control system to cope with current and future demand, as well as reduce the high level of manual intervention currently experienced.

 

Our Solution

In order to achieve the rates required and handle the volume of communications, 8 PLC (S7-300F series) systems were proposed, including a safety system supervisor with distributed safety IO racks using ET200SP.

Industrial Ethernet switches are employed for each PLC. For the industrial networks such as asi and Profibus, repeaters are positioned to improve communication over longer distances.

The automation system operated a Zenon SCADA system, allowing central monitoring and alarming, for four web clients – mobile or remote users. Hmis (Siemens TP-700 Comfort panels) were strategically located together with more than 70 docking stations for handheld mobile hmis to give the maintenance crew easy access to all areas of the plant for quick fault-finding.

 

Results

• Reduced manual intervention
• Increased production process
• Improved communication throughout warehouse
• Reduced wiring