Case Study: Perfectly Coordinated Processes at Ottobock
Project Overview
Ottobock SE & Co. KGaA, based in Duderstadt, Germany, is dedicated to maintaining and regaining customers’ freedom of movement. To keep up with growing demand, the company decided to modernise its shipping processes by installing a new automated system in collaboration with GEBHARDT.
The Challenge
Once on-site, GEBHARDT discovered that Ottobock’s shipping operations relied heavily on manual work. Many packages were stored and sorted by hand, which caused significant inefficiencies and downtime while waiting for parcel service providers to load shipments.
“The project was complex for several reasons,” explains Michael Hockenberger, Project Manager at GEBHARDT. “In addition to the large heterogeneous range of parcels, the automation and division of the warehouse into different storage patterns was a challenge. We also had to ensure that operations could proceed normally while connecting to the existing systems.”
Overall, Ottobock faced growing order volumes, frequent load fluctuations, and a highly manual workflow that made it difficult to maintain efficiency and compete in a fast-moving market.
The Solution
GEBHARDT implemented a comprehensive automated shipping system tailored to Ottobock’s needs. The solution streamlines parcel flow from incoming goods to shipping gates, enabling efficient handling of growing order volumes while integrating seamlessly with existing systems. At the core of the solution is an automatic mini-load warehouse, supported by advanced conveyor technology, which ensures smooth, reliable operations.
The automatic mini-load warehouse is built as a StoreBiter® OLS warehouse with two aisles, six levels, and twelve OLS units. This high-density setup provides flexible storage patterns to accommodate a wide variety of parcel sizes and types. Cartons enter the system via conveyors with integrated 3D scales, allowing pre-sorting according to the designated storage pattern in the racks.
Up to twelve StoreBiter® One-Level-Shuttles operate across the two aisles, retrieving cartons and delivering them fully automatically and just-in-time directly to the shipping vehicles via the shipping conveyor system, which includes integrated goods issue booking. Depending on the storage pattern and carton size, the warehouse offers up to 2,800 parcel positions, enabling Ottobock to achieve a fully automated and highly efficient dispatch process.
Our Results
The implementation of GEBHARDT’s automated shipping sorter and mini-load warehouse has transformed Ottobock’s dispatch operations. The system now handles up to 420 double cycles per hour in normal operation and up to 900 cycles in boost mode, allowing the company to efficiently manage increasing order volumes. With a capacity of up to 2,800 parcel positions and flexible storage patterns, the warehouse accommodates a wide variety of parcel sizes and types, reducing the need for manual handling.
Automation has significantly decreased manual sorting and improved overall efficiency, while pre-sorted deliveries ensure reliable just-in-time dispatch to the shipping gates. The seamless integration with existing systems has allowed operations to continue uninterrupted during implementation, giving Ottobock a robust, scalable intralogistics solution that supports both current and future growth.
„The cooperation with GEBHARDT was excellent. They reacted professionally and quickly to every request. Thanks to the GEBHARDT solution, our processes are significantly more reliable and faster, and can now optimally absorb peak loads and keep our customers happy.“
Jürgen Creutzig, Head of Technical Logistics & Infrastructure at Ottobock
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