A Fast-growing High-tech Manufacturer
Small Parts Warehouse
45,000
Storage locations with 130,000+ items stored
100
Storage and retrieval cycles per hour designed capacity
10 Months
Fast deployment
99.99%
Picking Accuracy
About the Client and Challenges
The client is a major European company with multiple production sites and a vast supplier network. Over recent years, rapid business growth and rising production volumes have placed increasing pressure on warehouse logistics.
Historically relying on manual processes, the client set out in 2023 to transform its intralogistics. The goals were clear:
-
Implement scalable solutions to keep pace with market demand.
-
Ensure high system availability for time-critical deliveries.
-
Gradually automate production supply with quick-to-deploy and high-performing systems.
-
Minimize IT complexity through tight integration with their SAP S/4HANA ERP environment.
Working closely with an experienced integration partner, the client chose the HaiPick System 1 featuring 6 HaiPick A42T ACR robots to automate small-parts storage and retrieval.
This system fully automates the small-parts warehouse, which now holds 45,000 ESD-compatible Euro containers, subdividable into up to eight compartments, supporting the storage of over 130,000 items.
-
Redundant Design for Maximum Availability: Every HaiPick A42T ACR has full roaming capability and can access any storage location in the system. This architecture ensures there is no single point of failure - if one robot becomes unavailable, others automatically take over its tasks, maintaining continuous operations and maximizing system availability.
-
Easy Scalability: Capacity can be expanded at any time by adding additional robots or rack modules, thanks to the system’s modular design and fast robot commissioning.
-
Enhanced Operational Efficiency: The automated system replaced disparate manual processes, reducing complexity and increasing picking precision.
-
Fast Deployment: The entire system was delivered within 10 months from design to go-live.
To minimize IT complexity, HaiPick System and conveyor subsystems were integrated directly with the client’s SAP S/4HANA ERP system. Stock and order management are handled seamlessly through the ERP, eliminating the need for multiple warehouse management systems.
As a further step in automation, the client also deployed 12 vertical lift modules, directly interfaced with SAP for efficient storage and retrieval of small and very small parts. For specific standalone use cases, a free warehouse management module supports operations outside the ERP scope.
Looking Ahead: Long-Term Transformation
The client sees this project as a milestone in a longer-term journey of gradual automation. The proven reliability, fast deployment, and modular scalability of the HaiPick System provide a strong foundation for further intralogistics enhancements as the business continues to grow.
“For our industry, availability, scalability, and compliance are paramount. The HaiPick System allows us to meet all three while keeping operations efficient and future-ready.”
Download the Case Study
