Flexible structures in production supply

Aloys F. Dornbracht GmbH & Co. KG produces premium fittings, accessories and overall solutions for the water zones in bathrooms and kitchens. For the »modular« factory, at the company’s headquarters in Iserlohn/Germany, psb developed and implemented a flexible integrated intralogistics system solution.


Aloys F. Dornbracht GmbH & Co. KG, Iserlohn | GER


Automated production warehouse with attached production supply; multi-aisle automatic small parts warehouse, conveyors, selektron WMS, selektron MFC, selektron SCADA

Design criteria

For reasons of reorganisation, Dornbracht decided on introducing a so-called »structure enhancement model«: hysically and organisationally separated individual areas are combined on a modular basis. This procedure is standard in both, single piece production and assembly of »exotics«, and serial production. The requirements were: automated processes, and reliable production supply by various small parts warehouse facilities.

The solution

The production area is supplied with small parts out of the warehouse in the »exotics « assembly. By that, the new logistics demands associated with the growing diversity of offered products can be met. Order picking is carried out directly at the small parts warehouse, or at a conventional order picking station respectively, depending on batch size and kind of product. As part of the project »establishment of assembly supply logistics for serial production«, self-manufactured surface units and purchased items are stored centrally, in a multi-aisle small parts warehouse (more than 26,000 locations).

The high performance achieved in the warehouse allows for the optimum supply of the individual production areas (inbound and outbound goods, galvanisation and polishing). Subsequently, 26 assembly workstations in production are provided automatically by transport carts. Conventional picking of single items is also possible. Consumables are organised via the Kanban principle. The overall system solution has been designed with long-term sustainability in mind, thus utilising ultra-modern energy recovery modules.

Both, the IT concept and the control concept have been designed with a high degree of modularity. The structure enhancers, as functional units, are mapped as PLC functions. The psb selektron software system controls the individual warehouse areas and organises the production supply. All processes are visualised by selektron SCADA.

A detailed description of the project can be downloaded just below.