AutoStore empowered by Kardex at SABAG in Switzerland

To optimize small parts logistics, Kardex is implementing a highly efficient AutoStore solution for SABAG Luzern AG at their headquarters in Rothenburg (Switzerland). In the future, the AutoStore system will be used to compactly store construction materials from the sanitary sector. 

Starting as a small, family-owned company founded in 1913, SABAG Luzern AG has grown into a major Swiss construction materials distributor, consisting of 7 autonomous firms controlled by a holding company. The fourth-generation family business today employs a workforce of more than 1,000 people across 41 sales and manufacturing sites.

SABAG is located in Rothenburg, Switzerland, with a total logistics area of 28,000 m² (including 2,000 m² for sanitary ware). All orders for Central Switzerland and Zurich are shipped from here.

Up until now, picking was done manually at SABAG in Rothenburg. However, in view of the growing assortments in the small parts sector, traditional warehousing using the “person-to-goods” principle has become increasingly challenging. To meet the increased requirements, the logistics center in Rothenburg is now to be automated. The search for a space-saving, scalable and long-term profitable small parts storage solution finally led Roland Wechsler, SABAG Head of Logistics Sanitary, to the AutoStore concept. In the future, the robot-based goods-to-person system will enable efficient handling of all small parts from the sanitary sector and thus considerably simplify replenishment, order picking, customer deliveries, workshop orders and returns processing at SABAG Luzern AG. The contract for planning and implementing the system was awarded to intralogistics expert and global AutoStore partner Kardex.

Maximum space utilization and efficiency

The AutoStore solution Kardex has planned for SABAG is precisely tailored for 3,100 storage bins on an area of just 100 m². The bins are neatly stacked on top of each other in an aluminum cubic grid system, maximizing storage density and enabling four times the capacity in the same footprint compared to traditional manual storage. Three battery-powered robots, which move on the rails of the grid, are used to handle the bins.

The battery-powered, high-speed robots pick up the bins, re-arrange them and present them at three ergonomically designed workstations – so-called Conveyor Ports – for picking and replenishment. Two of the Ports will be installed on the ground floor and used for picking and replenishment while the third Port will be installed on the upper floor and used for the supply of the assembly/workshop. This simplifies manual processes considerably and order-related picking is improved and accelerated.

The maintenance zone for the robots is to be installed on the upper floor on the existing concrete platform in a space-saving manner. The modular design of AutoStore allows for expansions in terms of throughput and storage capacity at any time without interrupting ongoing operation. Therefore, the system can grow with the company’s business needs.