Transfer Multisort Elektronik
Logistics Centre Rzgów
56,166
Storage Locations
150,000
SKUs
30,000+
Daily Order Lines
2,400
Totes Per Hour
Transfer Multisort Elektronik
To address the demands of a rapidly growing business, Transfer Multisort Elektronik (TME) partnered with Hai Robotics to implement a state-of-the-art automated warehouse solution. As a global company expanding rapidly, TME sought to maximize the efficiency of every square meter in their new logistics center, aiming to enhance picking accuracy and the overall efficiency of their ASRS system.
TME, with its highly automated existing warehouse and in-house integration expertise, set a high bar for performance and innovation. By collaborating with Hai Robotics, TME optimized storage density and throughput, ensuring their operations were ready for future scalability.
Challenges
TME faced three critical challenges:
- Space Optimization: Storing over 150,000 SKUs within a 2,400 sqm area requires a highly efficient and dense storage solution.
- High Throughput Requirements: Processing 2,400 totes per hour and handling 30,000+ daily order lines demanded exceptional performance and reliability.
- Scalability and Flexibility: Managing 150,000 SKUs of diverse shapes and sizes necessitated a system capable of adapting to growing business demands and varying storage needs.
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Operational Scale: 3,000 m² total, including a 2,400 m² storage area with 12.2m clearance and other operational zones with 5.8m clearance.
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Racks: 350~9950mm / 22 levels (reserved to increase to 11,450 mm / 25 levels in the future)
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Storage Capacity: 56,166 locations, expandable to 112,332 totes through stacking (+7,659 locations (3 levels) in the future reserved)
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Robots: 86 HaiPick A42T-L-E1-CE (10m reach, future-ready for 12m)
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Charging Stations: 23 sets of HaiCharger HRC-3000-E3-CE
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Workstations: 5 loading machines HAIPORT P10S-L-E2 + 5 unloading machines HAIPORT P10S-U-E2
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5 stacking machines + 5 de-stacking machines
High-Density Storage through Stacking: To meet TME’s ambitious storage requirements within the limited 2,400m² space, Hai Robotics installed 22-layer racks and introduced a two-tote stacking strategy. The system incorporates 5 stacking and destacking machines, seamlessly integrating with the warehouse’s workflows. This setup accommodates 56,166 storage locations, expandable to 112,332 totes.
Flexible Tote Handling for Diverse Product Types: Some of TME’s SKUs include totes with protrusions, creating unique storage challenges. To address this, the system and racks were engineered to accommodate protruding totes while maximizing space utilization.
Seamless Adaptability Across Areas: The telescopic A42T robots can operate effectively in both high-clearance (up to 10m) and low-clearance areas (5.8m), ensuring the system adapts seamlessly to varying warehouse conditions. Their ability to travel between zones at a reduced mast height of 5.73m further highlights the system’s versatility.
Enhanced Workflow Efficiency: Integrated 10 HaiPort units for seamless loading and unloading, achieving a processing rate of 2,400 totes per hour to support 30,000+ daily order lines.
Advanced Robotics: Deployed 86 HaiPick robots optimized for high-speed lifting, extended battery life, and continuous operation, ensuring consistent performance during peak periods.
Strategic Warehouse Planning: TME's warehouse features a high storage area with a 12.2m clearance initially reserved for a shuttle system. The space was later reconfigured for Hai Robotics’ telescopic A42T robots, enabling operations up to 10m today and prepared for expansion to 11.5m in the future.
10m Robots with 12m Racks for Future Growth: When TME partnered with Hai Robotics, they opted to install racks up to 12m high, allowing seamless scalability without disrupting current operations. This setup allows for the future addition of 7,659 locations, bringing the total to 63,825 locations and a maximum storage capacity of 127,650 containers.
Tailored Engineering: Partnered with TME’s in-house team to co-design a solution that aligned with their unique requirements, including support for both totes and carton boxes.
Redundancy for Safety: Designed robots capable of navigating across aisles and working in tandem, ensuring redundancy and uninterrupted operations during maintenance or disruptions. Even in the event of equipment malfunctions, operations would continue seamlessly thanks to intelligent system redundancy.
This project is a testament to innovation and collaboration. Hai Robotics' technology and expertise, combined with our team’s dedication, created a solution tailored to our needs. It not only meets today’s challenges but also prepares us for the future of warehouse automation.
This project is a testament to innovation and collaboration. Hai Robotics' technology and expertise, combined with our team’s dedication, created a solution tailored to our needs. It not only meets today’s challenges but also prepares us for the future of warehouse automation.
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Do you want to learn more about how TME enhanced their warehouse operations? Watch this engaging on-demand webinar, where our automation experts share valuable insights into the project, showing how Hai Robotics automation solutions can boost efficiency and storage density, enabling scalability.