Motan
A well-planned factory layout optimises material flow and efficiency in the new motan group logistics hall
Our customer
For any company that manufactures or processes plastic products, the motan group is a reliable partner for all peripheral equipment and system design. The group develops innovative material handling solutions for the plastics industry, defining and designing them on a wider scale and implementing them in a broader context. Founded in 1947 on Lake Constance, the group is now represented in over 80 countries with subsidiaries, branches and sales agencies. Motan has a staff of 600 globally and is a leading partner for process peripherals for the plastics industry. At the Isny site in the Allgäu region, the motan group employs 192 people covering all functions from development and human resources to production and logistics.
Additional storage and production space was to be created at this site in 2022. This is why the manufacturer of machine systems decided to build a new logistics centre on the existing production site in Isny im Allgäu. From this location, the entire production is now supplied with parts and components required for constructing machines. In cooperation with BITO-Lagertechnik Bittmann GmbH, a well-structured, highly efficient logistics area has been created that now optimises the internal material flow. The new hall serves as a supply centre for production. It was added to the overall complex which consists of several buildings and houses a wide variety of production facilities. The new logistics hall is connected to all production areas. The required parts of any size are moved to the workstations with the help of tugger trains.
Initial situation and customer requirements
The management decided to transfer the entire logistics operations to a new building. The customer requested that the new hall be built and furnished in accordance with the 5S's and lean manufacturing standards. Another key requirement was to maximise space efficiency and optimise the new building accordingly. The aim was to create a perfect layout for optimum material flow in a modern, clean, bright and clearly structured logistics hall and to connect existing production halls with the new logistics building. All processes had to be efficiently coordinated and perfectly harmonised, with improvements being visible at first glance.
Some impressions of our customer solution
Effizienzsteigerung auf einen Blick
Die BITO-Lösung
» Customised and coordinated storage solution for components in a variety of sizes
» Optimum storage conditions for both the smallest screw to bulky components such as housings or cable drums
» BITO XL 800 x 600 mm containers with runners are used for storing large components
» Divider bars enable safe and space-saving vertical storage of sheet metal on the lower shelving levels.
» Completely mesh-fenced rear sides on the upper racking level protect employees from falling objects.
» The pallet positions can accommodate both a full-size pallet or two half-size pallets.
» Drum racking for large and heavy cable drums, from which cable lengths can be reeled off as required.
On-site application and key features of our storage solution
- A multi-tier shelving installation has now multiplied the storage capacity for small parts on the same floor space.
- Small parts and accessories are stored on shelving levels in BITO XL containers and BITO RK storage and handling bins in a variety of sizes.
- At the customer's request, all bins and containers in the entire logistics area were supplied in customer-specific colours.
- The bins are fitted with dividers to create compartments of different sizes
- The multi-tier system includes a mezzanine floor at the front.
- A pallet transfer position on the second level is used to replenish materials and to transfer picking trolleys from and to the upper area.
- Stairways within the multi-tier facility connect the levels, making the upper level easily and safely accessible for order picking.
- Motan chose a custom colour for the entire shelving system in order to achieve a uniform overall picture.
- Small parts are transferred to the production area in BITO bins and containers and fed into BITO carton live storage racking along the production lines, ready for picking by the assembly staff.
Customer benefits
In what way has the BITO solution helped our customer to realise their full potential?
- Production and logistics areas are now perfectly connected, with a classic Kanban system ensuring optimum supply to production.
- The efficient warehouse design now saves a lot of space and reduces costs.
- Material wastage, which is unavoidable and must be taken into account in daily operations, has been reduced and the material flow has been optimised.
- Multi-tier shelving multiplies the usable floor space and thereby saves money.
- A clear layout and immediate product identification save a lot of time during order picking.
- The mezzanine floor creates additional storage space on the upper level and a separate order consolidation area on the ground floor.
"In BITO, we have found a reliable partner in terms of planning, implementation and support. In conclusion, we can say that together with BITO we were able to implement 100% of our objectives in terms of space consolidation, 5S and lean standards and were able to reduce unavoidable wastage as well as optimise our internal material flow. We are very happy with our cooperation with BITO. From the initial contact through to planning and implementation, as well as follow-up support, everything went very well. Another reason for choosing BITO was the range of bespoke solutions that BITO was able to offer us for our wide range of applications."
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