Case History

Viale della Tecnica, 2, 35026 - Conselve - PD

+39 049 5388211
+39 049 5388212

www.schneider-electric.com

Uniflair Spa

Mechanical industry, Electrical & Electronics

Since 1988, Uniflair has specialized in the design, manufacture and marketing of precision air conditioners, refrigeration systems and raised floors that have the specific function of providing advanced and reliable technological solutions for construction, Telecom-Internet systems and industrial refrigeration and comfort.

Starting with the domestic market, Uniflair's expansion has reached Europe and other continents. It is currently present in more than 60 countries around the world with its own facilities and through selected partners.

The Uniflair organization is articulated in the Conselve (Padua) headquarters, production and R&D site, in offices in Milan, Rome and Naples, and with subsidiaries in Spain, Germany, Hungary, South Africa, India and China.

Products:

WMS

StockSystem

WAREHOUSE LOGISTICS MANAGEMENT

Software for the management of logistics processes.

Schneider Electric

The numbers of Schneider Electric

Schneider Electric, formerly Uniflair, specializes in the design, manufacture, and marketing of precision air conditioners, refrigeration systems, and raised floors that have the specific function of providing advanced and reliable technological solutions for buildings, Telecom-Internet systems, and industrial refrigeration and comfort.

EMPLOYEES

PRODUCTION LINES

PRODUCTION PLANTS IN THE WORLD

AND MORE COUNTRIES

Logistics Experience

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CONSELVE (PD) PLANT

16,000 m2 production area
14 production lines
6500 pallet places
1000 m2 of racking

PLANTS IN THE WORLD
St. Louis R&D Center (USA)
Costa Mesa Plant (USA)
Bangalore Plant R&D Center (INDIA)
Zhuhai (China)
Shanghai R&D Center - China

In 2008, Uniflair Spa decided to reorganize the logistics flows related to the production process to improve the search for materials that supply the production lines with the aim of increasing the number of item codes managed, adopting wms software to manage routine operations within the warehouse.

The initial situation, before wms, was MANUAL and had the following limitations:

IN ACCEPTANCE

material in free-pass;
no quantity control;
identification and picking performed by line warehousemen; and
acceptance carried out by line warehousemen

STOCKING

no packaging specifications;
no shelf space optimization;
no material traceability.

PICKING

no pick lists;
specific warehouseman needed who knew all locations;
visual material search;
no route optimization.

GOALS

The objectives of the restructuring project are:

reduction of acceptance, storage and picking times,
reduction of errors for the supply of production lines,
increase in the number of pallet places available in order to increase the number of item codes handled.

SOLUTIONS

After careful software selection, they chose Replica Sistemi's StockSystem, in the standard version, with RF terminals to optimize goods entry, storage, picking and control operations.

The execution of operations in the warehouse is then entrusted to the RF system, which allows data to be transmitted in real time to the warehouse management system. Logistics operators work efficiently using RF (Radio Frequency) terminals interfaced with remote Access Point repeaters.

Stages of the collaboration

The project was carried out in 4 steps:

Analysis: April - July 2008

Phase 1: July - September 2008

Phase 2: from October 2008

Phase 3: August 2009

Analysis (April – July 2008)

The analysis was aimed at:
A - Creating packaging specifications
B - Shelving optimization
C - Detailed mapping of the warehouse

A. THE FOLLOWING SPECIFICATIONS OF EACH WERE ANALYZED FOR THE CREATION OF THE DIFFERENT TYPES OF PACKAGING:

Piece size
Quantity pieces per UDC
Type of PACKAGE
Total size UDC
Width
Depth
Height

The packaging mainly used is the paretal due to its many advantages:
in operational terms:
> ease of picking;
> ease of storage;
> handling
and environmental (compliance with ISO14001 certification):
No stretch film
No cardboard.

B. SHELVING OPTIMIZATION

An analysis of the existing shelving and calculation of the required positions for each CONTAINER TYPE was done:

CMM calculation
STORAGE Calculation.

The lay-out of a new shelving unit with moving and adding shelves was studied. BAR CODE LABELS were printed and applied to the different locations and computerized. In addition to increased shelf capacity, greater storage flexibility was achieved by defining "Containability." Containability is the definition of the cell size and the Container Types it can contain (each Container Type contains itself and Container Types of smaller size).

C. WAREHOUSE MAPPING AND COMPUTERIZATION

A warehouse mapping of the Acceptance, Storage, and Picking areas was then redefined.

The results of this initial analysis were important. The total storage capacity was increased by 33% (from 203 previously available locations to over 300 with the new layout) while maintaining great flexibility thanks to the automatic management of volumes and the definition of Container Types (one cell can contain multiple codes with different packaging).

In addition, material previously "stored" on the line was moved to shelving, thus creating more space available to line operators.

An additional benefit was achieved through improved picking capacity.

From 72 picking locations with the old lay-out, this has increased to 87 available locations (21 percent increase) with the new lay-out; this allows for a greater quantity of picking codes allowing for faster preparation of requirements by the warehouseman.

Some picking locations are managed at fixed locations while the others are random.

Phase 1 (July – September 2008)

Activating Merchandise Receipts and Sample Line Management - August 2008

Activation of global raw material receipt
Storage in lost stock areas for production lines not covered by the Phase I project
Planning Replenishment Line activated
Production line replenishment with lists and maintenance of line inventories
Line loading of components from positions not managed by Stocksystem prior to finished product pouring (Consignment and RIP)
Deferred component matriculation
Consignment of line consumption automatically from Finished Product Pouring
Pouring Finished Product with Matriculation Detection
Finished Product storage in stock loss area
Withdrawal of any spare parts from inventoried positions with RF free discharge (checking whether the spare part is committed by production)

Phase 2 (July – September 2008)

Activating Merchandise Receipts and Sample Line Management - August 2008

Phase 3 (July – September 2008)

Activating the Shipment Flow

Mapping/Inventory Whole Inventory Finished Products
Pouring Finished Product with Serial Number Detection
Finished Product storage in mapped locations
Shipping Finished Product with pick lists and serial number detection

Achieved advantages:

Increase in the number of pallet places available in the areas of:

Reduction in the time of:

You are no longer bound to the knowledge of the warehouseman
There are no more "ghost" materials
Increase in the number of item codes handled: from 4,000 in 2009 to about 11,000 in 2012.

Uniflair Spa

Products:

The numbers of Schneider Electric

Logistics Experience

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We selected some of the leading companies supplying a WMS solution. In the final choice, an aspect of reliability prevailed, as well as the conviction that we had found a partner who would follow us both at the level of system implementation but also organizational growth.

Luca Masiero

Needs

Stages of the collaboration

The project was carried out in 4 steps:

Analysis: April - July 2008

Phase 1: July - September 2008

Phase 2: from October 2008

Phase 3: August 2009

Analysis (April – July 2008)

The analysis was aimed at:
A - Creating packaging specifications
B - Shelving optimization
C - Detailed mapping of the warehouse

Phase 1 (July – September 2008)

Activating Merchandise Receipts and Sample Line Management - August 2008

Phase 2 (July – September 2008)

Activating Merchandise Receipts and Sample Line Management - August 2008

Phase 3 (July – September 2008)

Activating the Shipment Flow

Achieved advantages:

Information request

Uniflair Spa

Products:

The numbers of Schneider Electric

Logistics Experience

AttentionTo watch the video, you must authorise cookies (bottom left button 'Cookie Settings') and then refresh the page. SUBTITLESSubtitles can be displayed in Italian, English and German. To activate them, click on the settings button (gear icon at bottom right), subtitles, language choice.

We selected some of the leading companies supplying a WMS solution. In the final choice, an aspect of reliability prevailed, as well as the conviction that we had found a partner who would follow us both at the level of system implementation but also organizational growth.

Luca Masiero

Needs

Stages of the collaboration

The project was carried out in 4 steps:Analysis: April - July 2008Phase 1: July - September 2008Phase 2: from October 2008Phase 3: August 2009

Analysis (April – July 2008)

The analysis was aimed at:A - Creating packaging specificationsB - Shelving optimizationC - Detailed mapping of the warehouse

Phase 1 (July – September 2008)

Activating Merchandise Receipts and Sample Line Management - August 2008

Phase 2 (July – September 2008)

Activating Merchandise Receipts and Sample Line Management - August 2008

Phase 3 (July – September 2008)

Activating the Shipment Flow

Achieved advantages:

Information request

Attention
To watch the video, you must authorise cookies
(bottom left button 'Cookie Settings') and then refresh the page.
SUBTITLES
Subtitles can be displayed in Italian, English and German. To activate them,
click on the settings button (gear icon at bottom right), subtitles, language choice.

The project was carried out in 4 steps:

Analysis: April - July 2008

Phase 1: July - September 2008

Phase 2: from October 2008

Phase 3: August 2009

The analysis was aimed at:
A - Creating packaging specifications
B - Shelving optimization
C - Detailed mapping of the warehouse