Moss, lichen, soot stains, caked-on dust: When the going gets tough, it’s time to use a Kärcher. Not only has KÄRCHER made it into the Duden dictionary as a verb, but KÄRCHER is also the number one name in cleaning technology—worldwide. The family-owned company was founded in Stuttgart in 1935 and moved to nearby Winnenden in 1939, where it remains headquartered to this day. The corporate group comprises more than 160 companies that employ around 16,000 people in 82 countries and generated 3.294 billion euros last year—more than ever before in the company’s history. io is also contributing to this success: The Heidelberg-based planning service provider has been advising KÄRCHER since 2021. “Our collaboration began with the verification of a concept study,” recalls Christian Schindler, Senior Consultant at io. This involved the expansion of the high-bay warehouse at the Global Parts Center site in Obersontheim, Swabia.
Tripling of storage capacity
It is KÄRCHER’s only central warehouse for spare parts and accessories. More than three million delivery note items are shipped from here to destinations around the world each year. Its storage capacity needed to be expanded due to both static and dynamic growth. To reduce transport distances, the inventory was also to be moved from the external warehouse to the new high-bay warehouse. “First, we assessed the requirements, after which we modified the concept slightly to adapt it to KÄRCHER’s needs. We decided to maximize storage capacity in the high-bay warehouse, which is why we opted for double-deep rack bays,” Schindler explains. “We integrated the new high-bay warehouse into the existing logistics system. To supply it—and to connect it to the ergonomic picking stations—we integrated an electric monorail system with eight vehicles in the feed zone.”
"At the picking station, the height of the load carriers being processed can be adjusted using a lift table, which also benefits employee health." With the expansion of the high-bay warehouse by more than 31,000 storage locations for wooden pallets and mesh boxes, storage capacity for spare parts and accessories has tripled. In addition, the flow of goods and replenishment for small-parts picking have been optimized—on time and within budget. The measures were implemented from January through December 2022, which was quite a challenge, as Schindler admits: “2022 was a year of international crises—with the result that important parts were unavailable. Control components for conveyor technology were out of stock worldwide. We had to find alternative solutions. For example, the parts needed to commission the storage and retrieval machines were removed from test benches.”
Each year, approximately 11,000 kilometers in transportation distances are saved
By eliminating the need for an off-site warehouse, the Global Parts Center saves approximately 11,000 kilometers in transportation distances each year. This is a win for the environment that aligns with KÄRCHER’s commitment to sustainability. The same is true of the new service center in Ahorn near Würzburg, which meets KfW 40 sustainability standards. It is the only service location in Germany—and is responsible for maintenance and repair services for products from ten European countries. As a logistics planner, io supported the construction and commissioning of the approximately 10,000-square-meter complex, as well as the relocation of the inventory. The new Service Center significantly reduces the time required for repair services. Administrative overhead is also reduced. Furthermore, the high degree of automation eases the workload on employees.
Manual processes have been replaced by highly automated systems
“With the new Service Center, manual processes have been replaced by highly automated systems. This advancement now makes it possible to achieve short turnaround times despite increasing performance demands. Customers, in particular, benefit from faster and more efficient workflows, which leads to a significant improvement in service quality,” explains Lukas Witte, a consultant at io. “The devices are transported from the truck via a conveyor belt directly to the receiving stations and then into the warehouse. From there, they are automatically routed to the repair staff. In addition, replacement parts are routed from the warehouse to workstations set up specifically for product groups. Frequently used replacement parts are stocked on a shelf behind the workstations. These can be restocked as needed using an automated guided vehicle.”
Everything is controlled via SAP EWM and a proprietary system from KÄRCHER. Staff received extensive support and training for working in the new, highly automated facility, with io providing assistance during commissioning and the initial ramp-up. The new Service Center went into operation at the end of 2023. Final acceptance took place in February of this year.
Meanwhile, the groundwork for further collaborations has already been laid: io is currently supporting the implementation of the future high-bay warehouse at the Bühlertal production site—just like KÄRCHER itself: at full speed! The go-live is currently scheduled.
