Case Study: Precision in Perfection at HEIDENHAIN
Project Overview
DR. JOHANNES HEIDENHAIN GmbH, based in Traunreut, Germany, is a leading international manufacturer of precision measurement and control equipment. The company decided to modernise its intralogistics systems to meet growing industry demand and maintain efficiency across its warehouses. With over 130 years of history and more than 8,600 employees across 30 subsidiaries worldwide, HEIDENHAIN relies on advanced automation to support production of linear and angle encoders, rotary encoders, and CNC controls for industries such as semiconductors, machine tools, and plant automation.
The Challenge
HEIDENHAIN’s existing intralogistics systems were no longer sufficient to keep up with increasing order volumes and diverse product sizes. Manual processes predominated, limiting throughput and increasing downtime. The company required a modern, scalable solution that could handle a high number of storage and retrieval operations while connecting seamlessly to existing SAP systems. In addition, HEIDENHAIN needed to expand storage capacity, improve picking efficiency, and optimise material flow across multiple floors without disrupting daily operations.
The Solution
GEBHARDT Intralogistics Group implemented a fully integrated intralogistics upgrade at DR. JOHANNES HEIDENHAIN GmbH, combining container and pallet delivery systems with modern automation technologies. The solution connects the existing container warehouse with an updated pallet high-bay warehouse and incorporates seven automated guided vehicles (AGVs) along with SAP Extended Warehouse Management (EWM), including the Material Flow System (MFS) module.
This modernised system ensures smooth, uninterrupted material flow across three floors, automates storage, retrieval, and delivery to workstations and shipping areas, and accommodates a wide variety of pallet and carton sizes. By connecting all components digitally, Heidenhain can operate efficiently, reduce manual handling, and increase throughput.
To update DR. JOHANNES HEIDENHAIN GmbH’s systems, firstly GEBHARDT Intralogistics Group replaced and extended their container delivery components by 180 meters using a variety of new elements. This change consisted of installing a new conveyor system, scaling the number of workstations from nine to 14
standing picking workstations, and connecting the new equipment to the existing container warehouse.
The material flow was connected over three floors to create a steady and quick flow of goods throughout the warehouse.
Stacking and de-stacking devices, lifters, transfer units, and chain and accumulating roller conveyors were all introduced to streamline Dr. JOHANNES
HEIDENHAIN GmbH processes. By replacing manual methods with automation, downtime can be minimised, and order accuracy can be improved.
Automated Guided Vehicles (AGVs) were also used to reduce labour costs, improve safety, and connect the various processes to create a fully automated goods delivery system.
This new intralogistics arrangement would not be possible without perfectly coordinating all the systems. To ensure this, GEBHARDT Intralogistics Group worked closely with SAP engineers, IGZ, who are based in Falkenberg. With their help, the team established a connection between the new intralogistics systems and the material flow to relay information back to employees.
Our Results
The modernised intralogistics system has transformed HEIDENHAIN’s warehouse operations. High-performance, flexible storage systems and lean processes have increased throughput and operational reliability. Standardised processes ensure consistent quality and order accuracy, while automation has reduced manual labour and safety risks.
The combination of digital intelligence, robust equipment, and integrated AGVs has positioned HEIDENHAIN for future growth, enabling the company to respond to market demands with greater efficiency and precision.
„With GEBHARDT Intralogistics Group, we always felt as though we had a dependable
partner by our side.“
Dr. Günther Obermeier, Head of Building Technology at HEIDENHAIN
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