Swisslog’s new AutoStore automated warehouse solution for Komatsu is delivering enhanced uptime and energy-efficiency to a new spare parts warehouse in Victoria.
A new Swisslog AutoStore grid-based automated warehouse solution is delivering energy efficiency to Komatsu’s new spare parts Fulfilment Centre in Tarneit, Victoria.
The new purpose-built warehouse is designed to store small-to-medium parts for machinery used in the construction sector, a major market for Komatsu in Victoria.
“Construction is a demanding sector, so we required a system with high levels of uptime,” said Komatsu’s General Manager, Warehousing, Hennie Van Der Merwe.
“Seeing AutoStore deliver 99.9 per cent uptime globally, and Swisslog’s local projects regularly seeing higher numbers up to 99.99 per cent, gave us the confidence that we will be able to best serve our customers at all times.”
The AutoStore solution has been highly commended in the Supply Chain Management category of the 2024 Australian Supply Chain and Logistics Awards (ASCLA).
In addition to the construction sector, Komatsu provides essential equipment, technologies, and services to the mining, energy, government, waste, and quarry industries.
The company’s purpose is to create value through manufacturing and technology innovation, to empower a sustainable future where people, businesses, and their planet thrive together. Komatsu specialises in the sale of equipment, and the ongoing support of that equipment via the distribution of spare parts, which is where the new Swisslog solution will provide greater efficiencies, allowing Komatsu to deliver better service to customers.
AutoStore is a unique and simple grid-based automation solution that uses robots and bins to quickly process small parts orders.
It provides better use of available space than any other automated system due to its unique design that enables direct stacking of bins on top of each other and storage of multiple SKUs in a single bin. Over time, the system naturally learns which products have a higher rotation, storing them on the top layer to ensure faster picking times.
Swisslog is one of the world’s leading AutoStore integrators, with hundreds of projects worldwide, backed by support, expertise, and software.
Energy-efficiency
Komatsu’s new facility sought from the outset to achieve a 5-star environmental rating, and the energy-efficiency of the Swisslog AutoStore system was a contributor to minimising total energy consumption of the building to help achieve this rating.
“Each robot in the AutoStore is extremely efficient, using just 0.1kW of energy per hour. Six robots use about the same energy as a toaster,” says Swisslog Head of Sales and Consulting, Sean Ledbury.
This low energy consumption, combined with low maintenance costs makes for a favourable total cost of ownership (TCO).
“With a low investment, AutoStore achieves efficient processing at integrated goods-to-person workstations,” says Sean.
“People don’t need to walk long distances to pick products, the robots deliver goods directly to pick stations to reduce picking times.”
Hennie adds, “The Swisslog solution was highly energy efficient, a key consideration for gaining the building’s 5-star environmental rating.
“It was also a highly compact, space-saving solution, allowing us to consolidate all construction spare parts storage into a single facility, saving valuable real estate space and costs.
“The solution met sustainability criteria, with a low footprint. Assuming the automation solution is operational for a 12-hour day, five days a week, for the full 52 weeks in the year, total annual power consumption would be 3,744 kWh (less than 10 kWh per day).”
Intelligent software
Controlling the automation solution is SynQ, a proprietary software developed by Swisslog that stands for synchronised intelligence. It synchronises people, process, and machines for efficient operations. In addition to being a Warehouse Management System – WMS, it performs the task of a WCS – Warehouse Control System , or MFS – Material Flow System, and can seamlessly interact with ERP (Enterprise Resource Planning) and e-shop systems.
Swisslog has developed its own unique AutoStore-SynQ integration, to add further benefits to customers implementing warehouse automation and looking to further optimise performance.
“Swisslog’s SynQ software seamlessly integrated with our own WMS, and together with AutoStore’s in-built software, the system learns from existing performance and orders, and optimises storage to create further efficiencies to operations,” Hennie says.
Customised solution, standardised components
The Komatsu spare parts fulfilment centre was part of Swisslog’s standardised AutoStore offering. Standardisation increases efficiency, reduces time-to-market, and allows for the most cost-effective solution.
“Swisslog can then use these standard components, and configure a solution to suit each unique application, which is what we did in close collaboration with Komatsu,” says Ledbury.
Komatsu’s automated warehouse included:
Accommodation and functionality prepared for click-and-collect, so that construction companies can place an order overnight and pick it up early the next morning before going to site. The solution also featured order buffering, which means that orders could be prepared in advance of being required and set up for click-and-collect later, leading to quicker turnaround times and a more efficient overall system. This was all controlled by Swisslog’s intelligent SynQ software.
Consolidation. Part of this solution was consolidating during the picking process allowing a more customer focussed solution. Komatsu customers want all parts to be delivered in a single consignment. The picking process applied with SynQ makes picking four orders while simultaneously consolidating to a single consignment possible.
Increased storage and retrieval efficiency. In addition to using a smaller footprint, the Swisslog AutoStore solution with segmentation meant Komatsu could reduce the need for additional small parts storage as well as bulk storage of fast-moving parts. The efficiency of retrieval and put-away process allows for efficient replenishment into the Swisslog AutoStore.
“Swisslog’s team had an in-depth technical knowledge of such complex projects and took the time to understand Komatsu’s unique requirements,” says Hennie.
“This high level of expertise and dedication to finding the optimum solution has helped forge a strong relationship between the two companies, and we look forward to expanding this partnership with Swisslog in the future.”
Future growth
The AutoStore solution is designed to save space, increase efficiency, and allow for future expansion. Advantages include:
Space saving system. Up to 30 per cent, when compared with other technologies.
The AutoStore adapts to Komatsu’s growth plans. The Phase 1 grid size is designed to cater for 2027 volume at 17,900 bins, and is expandable to 22,000 bins, plus it can easily be realised during operation.
Optimal design of the AutoStore in all stages of expansion to the existing building geometry.
Intelligent order orchestration through Swisslog’s SynQ software.
“Swisslog has built this warehouse automation system with the capacity to expand as Komatsu expands, which aligns with our growth plans, and enables us to ramp up capacity to meet demands,” said Hennie.
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