Intralogistics system by psb makes children’s hearts beat faster

The core components of the integrated intralogistics system, which started its operation in the year 2013, are a shuttle warehouse (12 aisles) with 72 vario.sprinter shuttles, and 16 rotapick high performance order picking systems.

In the warehouse (20 m high, extending over 75,000 m²), 130,000 cartons and bins are stored, with sizes between 600 x 400 mm and 800 x 600 mm. Each of the 12 aisles (32 levels per aisle) is serviced by six vario.sprinter shuttles, plus two shuttle lifts.

The warehouse fulfils two functions:
(1) complete and opened article cartons are stored, and
(2) complete and started order cartons are buffered.

Three pre-zones, which are arranged above each other, allow for an uninterrupted and therefore extraordinarily efficient material flow between the warehouse and the order picking area.

At the dynamic rotapick systems, the operators pick far more than 1,000 items per hour. An outstanding feature of this system is that the items can be put directly from the source carton into the target carton, which means that each item is handled only once.

Another clear benefit of the rotapick is that the items are picked in a specified sequence, so that a laborious subsequent sortation at the points of sale is not necessary. At the order picking workstations, 60 source cartons and the same number of target cartons are buffered and made available for the operator in the requested order and sequence.

The psb selektron software application, which is interfaced to Mayoral’s ERP system, organizes the control of the installation and the warehouse management, plus the control of the entire flow of materials.

Thanks to the powerful intralogistics installation, each day up to 1,600 orders can be handled and shipped. In both business seasons, summer and winter, there is a variety of 15,000 different articles, which have to be entirely exchanged upon the change of the season.

Each year, Mayoral stores and ships in total 21 million items to 8,000 points of sale in 63 countries across the world. With the psb highly flexible integrated intralogistics system, both, initial allocations with large quantities, and significantly smaller subsequent deliveries can be handled with a high degree of economic efficiency.

Finally, the impressive integration of the new Mayoral corporate video expresses the degree of customer satisfaction with the new intralogistics system. And this fills us with pride: