Fully-automated warehouse management thanks to 2D LiDAR sensor technology at thyssenkrupp Rasselstein

The digitalization of logistics demands innovative approaches in order to raise efficiency, transparency and safety to a new level. This was achieved impressively at thyssenkrupp Rasselstein: Using state-of-the-art software and sensor technology, a logistical bottleneck was turned into a high-speed network. While the precise LiDAR sensors from SICK provide the basis for reliable real-time data, the high-performance intralogistics software from IdentPro ensures a seamless integration and transparency throughout the material flow in the warehouse.

The challenge: sources of error and efficiency losses

The storage areas in the production facilities at thyssenkrupp Rasselstein are extensive and complex. thyssenkrupp Rasselstein has been around for over 260 years and is the world's largest production site for packaging steel. On an area of around 1.5 million square meters, 2,400 employees are working to produce about 1.5 million tonnes of tinplate per annum. Before implementing the new system, it was necessary to manually scan stock movements. This required the forklift drivers to exit their vehicles – a time-consuming process that was susceptible to errors. Variances between the physical and digital stock level can have far-reaching consequences on production planning. Furthermore, each time this procedure is performed there is a potential risk of an accident despite comprehensive safety measures.

To eliminate these vulnerabilities, the company turned to IdentPro. IdentPro offers innovative software solutions for intralogistics that achieve complete transparency and increased efficiency in warehouses through real-time digitalization and process automation. At the center of the project at thyssenkrupp is the "Warehouse Execution System" (WES), which in combination with, amongst other things, the high-precision 2D LiDAR sensors from SICK ensures a fully automatic recording of all stock movements. The manned forklift trucks were equipped with IoT kits. This enables the sensors to provide precise position data in real time which are combined in the IdentPro software to form a digital twin of the environment.

The picoScan150 and LRS4000 models from SICK, in particular, play a decisive role in this: The picoScan150 is characterized by its long scanning range and at the same time high angular resolution and precision in contour navigation. The LRS4000 was specially designed for the demanding conditions in outdoor areas, including adverse weather conditions as well as working ranges of up to 300 m. 

Benedikt Heinen, Key Account Manager at IdentPro, explains: "The LiDAR sensors from SICK are an important pillar of our solution. Their precise data provide the foundation for the high reliability that characterizes our system. This makes the work of the forklift drivers easier and safer as they no longer need to exit their vehicle to record stock movements."

The solution: connected sensors with flexible software

The implementation is impressive not only on account of its technical ingenuity, but also the seamless integration into existing systems. The forklift drivers see on a display both their current position and the next pickup and drop off point. All movements are recorded automatically without the need for additional work steps. By implementing the new technology, thyssenkrupp Rasselstein was able to achieve several goals at the same time:

• Increased efficiency: Stock movements are recorded fully automatically, which significantly reduces the time involved.
• Fewer errors: The automatic recording minimizes human error and ensures a consistent stock level synchronization.
• Higher occupational safety: Forklift drivers no longer need to exit their vehicle to perform scans.
• Future viability: The system is flexible and scalable, which makes it a sustainable investment.

The cooperation between IdentPro and SICK demonstrates how technological synergies can revolutionize processes. In doing so, SICK delivers not only technology but liaises closely with the software manufacturer, which benefits both parties. Daniel Salas, Key Account Manager Mobile Platforms at SICK emphasizes the collaborative nature of the partnership: "We work hand in hand with IdentPro on optimal solutions. The practical experience we gain flows directly into the further development of our sensor technology."

This project clearly illustrates how innovate technologies can revolutionize logistics – more efficient, safe and forward-looking than ever before.

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