KNAPP Implements Smart Pallet Handling for Cummins in Lindesberg, Sweden

KNAPP has delivered a smart pallet handling automation solution for a manufacturing site in Lindesberg, Sweden, demonstrating its expertise in flexible, end-to-end production logistics. The solution integrates autonomous mobile robots (AMRs), automated storage and retrieval systems and intelligent software to optimize material flows, improve safety and support responsive manufacturing operations. Cummins selected the solution to meet the site's complex production and logistics requirements.

Efficient warehouse automation for end-to-end goods flows

At the 55,000-square-meter (592,015-square-foot) plant in Lindesberg, Sweden, Cummins produces front and rear drive axles for the trucking industry. Due to their wide range of products and complex manufacturing processes, Cummins decided to automate the location's particular one of goods flows with KNAPP. A fleet of 15 Open Shuttle Fork AMRs is responsible for transporting pallets within the warehouse, processing up to 2,000 transport orders each day. Furthermore, a new double deep high-bay racking system for pallets and an automated small parts warehouse - both outfitted with stacker cranes - automatically store and retrieve pallets and containers. The picking area includes 190 picking stations, which are supplied just in time by the Open Shuttle Fork fleet. The software behind the efficient goods flows is a powerful combination of KiSoft One and the KiSoft FCS fleet control system. "The biggest advantage of the solution in Lindesberg is that the warehouse is now fully automated. The AMRs transport the pallets automatically, the AS/RS keeps track of inventory, and the host creates and sends the transport orders to the warehouse control system," explains Raj Kamal, Engineer Industrialization EU at Cummins Inc.

Autonomous mobile robots for just-in-time production logistics

The Open Shuttle Fork fleet transport pallets between goods-in, the high-bay pallet racking, the automated small parts warehouse for and the picking area. The AMRs also take back empty pallets. Pallets delivered to the picking area are placed at one of three different heights - either on pallet stands or on the floor - significantly improving the ergonomic situation for employees. For the plant in Lindesberg, the Open Shuttle Fork means end-to-end automation of the flow and a safer work environment. The autonomous mobile robots were integrated without any need for construction in the building and new processes can be implemented flexibly as needed.

KiSoft One & KiSoft FCS: software package for transporting goods

A software package tailored to meet local requirements digitalizes warehouse logistics at the Lindesberg location. KiSoft One is the comprehensive software platform for the company's warehouse logistics across all levels of their system hierarchy, from warehouse management and control down to machine control. An interface to the Cummins host system connects all processes directly with the MES system. Meanwhile, KiSoft FCS (Fleet Control System) manages the Open Shuttle Fork fleet while also controlling and optimizing transport orders, offering a digital overview of all vehicles. While the automation solution was being implemented, KNAPP developed new functions for KiSoft FCS to meet Cummins' on-site requirements and ensure that their transport processes run smoothly.

The solution at a glance

• Autonomous mobile robots: 15 Open Shuttle Fork AMRs for internal pallet transport
• High-bay racking system for pallets: With stacker crane, 2 aisles double deep, 5 levels, 2,238 storage locations
• Automated small parts warehouse (AS/RS): With stacker crane, 1 aisle, 19 levels, 7,920 or 15,840 storage locations depending on container size
• Picking area: 190 picking stations with pallet stands
• Conveyors: Pallet conveyor system in goods-in and the high-bay racking system, Putaway conveyor in automated small parts warehouse
• Software: KiSoft One with an interface to the customer's MES system, KiSoft SCADA warehouse visualization, KiSoft FCS for controlling the AMR fleet