Optimising Material Flow at Ravensburger AG's Logistics Center
Ravensburger AG
Ravensburger AG, a leading German company in games, puzzles, toys, and publishing, is renowned as the European market leader in jigsaw puzzles and the top games brand in Germany, offering a diverse range of over 850 titles for children and adults. To support its expanding product range and daily shipment of over 100,000 items, Ravensburg Spieleverlag GmbH undertook a complete revision of its material flow concept in the shipping area. By integrating powerful new conveyor technology from GEBHARDT, achieving throughputs of up to 1,200 cartons per hour, the project focused on optimising material flow, ensuring fast and smooth processes, and making the best use of available space.
Making Ordering and Shipping More Effective
The newly redesigned shipping department combines both bulk packing and pick-and-pack operations to create a more streamlined and efficient process. A central goal of the redesign was to maximise the available space within the existing building. By reorganising workflows and freeing up previously occupied areas, Ravensburger was able to significantly expand its on-site storage capacity. This allowed the company to eliminate the need for an external warehouse, leading to more efficient operations, reduced logistics complexity, and substantial cost savings.
Control Configuration
The new setup includes a PLC (Programmable Logic Controller) system, a material flow computer, and a system visualisation platform, all designed to ensure efficient and transparent operations. These components work together to control and monitor the flow of goods in real time. Additionally, the dispatch processing was fully integrated with the existing Warehouse Management System (WMS), allowing for seamless coordination, faster processing times, and improved inventory accuracy.
Remote Maintenance and Online Access
To ensure the material flow maintains high availability, several emergency strategies have been implemented. These strategies help minimise downtime and quickly address any issues that arise. The system includes a 2D visualisation of the entire facility, where any faults are immediately highlighted for quick response. Additionally, remote maintenance capabilities and online access are implemented, allowing technicians to perform troubleshooting and resolve problems remotely, ensuring continuous, efficient operation.