MES rollout
Scalable warehouse processes at Behrens-Wöhlk
The Behrens Group is a leading wholesale partner for wood and interior construction products with 13 locations. Its product range extends from panel materials and doors to fittings as well as drywall and cavity wall systems. A high-performance logistics infrastructure ensures strong product availability, fast delivery processes and consistently high process quality.
To structurally support further growth, the company invested in the expansion of its central warehouse at the Großenhain site and implemented a completely redesigned logistics solution. A fully automated floor storage system for doors, frames and floor elements from Barbaric was installed there. dmaic software developed a customized solution designed to meet the requirements of the hybrid warehouse concept consisting of high-bay storage and floor storage.
Product damage
Picking errors
Picks per hour
Warehouse management in the new central warehouse
The core of the concept is the seamless interaction between two warehouse environments: the automated floor storage system works directly with the high-bay warehouse, which is operated manually using narrow-aisle forklifts and serves as the replenishment base.
As soon as stock in the floor storage system falls below a minimum level or an order cannot be fulfilled from the available inventory, items are manually retrieved from the high-bay warehouse and transferred to the floor storage area. The key challenge was to combine both areas into one end-to-end picking process.
Scalable processes based on a proven system architecture
Picking is carried out using digital pick lists on Android devices. Employees are guided through the process step by step, reducing error rates and accelerating workflows. Warehouse movements are recorded and reported back in real time by scan. Replenishment from the high-bay warehouse to the floor storage area is managed through pick lists on mobile devices. Replenishment quantities are calculated in the MES based on control data from the Bero system. Once calculated, pick lists are automatically created for replenishment and guide employees through the required work processes. The system supports two types of picking: tour-independent picking for prioritized customer orders and tour-based picking with an optimized unloading sequence.
Measurable process and time gains
The results are clearly measurable: accelerated processes, immediate response options for critical stock levels, shorter transport routes and a significant reduction in incorrect inventory transactions.
Bidirectional interfaces to Bero and Barbaric ensure real-time inventory synchronization and complete traceability. Planning reliability increases and delivery performance becomes more stable.