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dhl-exel-slovakia

DHL Exel Slovakia

    • Navigating a worker to a designated position in the warehouse.

    • Picking parts for multiple cars by one worker at the same time.

    • Automating parts ordering processes.

    • Checking the correctness of picked parts.

    • Preserving the original shelves and large boxes.

  • For navigation and sequencing of multiple cars at the same time, we used programmable RGB LED strips. Using different colors and the number of lit LEDs, we distinguish individual cars and the number of parts to be picked.

    • The cart is divided into 3 color-coded sections. Each contains parts for a different car.

    • The worker is navigated to the positions via programmable RGB LED strips.

    • Paper prescriptions were replaced by digital ones with control of already loaded parts.

    By combining the pick by light and push to light methods, we designed and created a unique Manipulate 2 Light system, which is protected by industrial design: PUV50145-2014. We achieved control of picking from larger positions by using a laser sensor with a range of up to 10 m.

    • The number of LED lights indicates the number of parts that the worker has to pick.

    • Control of picking using a laser sensor with a range of up to 10 m.

    • Switch off after detection of selection.

    • The M2L system was put into production within 3 months.

    • The system is currently deployed in a 4000qm warehouse in eight separate workstations.

    It is used to pick more than 2000 different parts for three car models of different brands.

    • High modularity and customization

    • Quick installation

    • Specify and resize positions with a simple swipe

    • Distinguish protocols using different LED colors

    • Real-time overview of stock levels

m2l-riesenie-dhl

Growing production, higher demands and new challenges

The constant increase in production at the Bratislava car plant, the demands for flexibility, the shortage of personnel and the pressure to improve quality presented DHL with new challenges.

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The key was the need to simplify and speed up the picking of parts according to the production plan for a specific vehicle at the commissioning workplace.

0,0001 %

current error rate

-85 %

new employee training time

Results

pick-to-light-dhl

Paperless workplace, lower error rate, smoother flow

The deployment of the M2L system reduced the training time for new workers by 85%, increased picking accuracy and reduced the number of errors.

The workplace could be expanded without the need for new employees, processes were automated and a paperless environment was created with easy training of new operators.

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DHL has been using the solution since 2015 and even created a recruitment video from the workplace with M2L.

In the next phase, the project is expanding to include worker navigation when placing parts in carts, image recognition as a final check and the integration of augmented reality for recording picked parts in real time.

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DHL is also expanding the cooperation to include other M2M Solutions solutions – WMS, TLS and custom-developed applications.

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