Logistics Planning
(E-)Commerce & Fashion
Greenfield Warehouse for Processing Fashion (Returns)
Implementation support by Metroplan – With communication and interface management
During logistics implementation, we support all discussions, coordination and approvals between you, the material flow technology companies carrying out the work, the parties involved in other trades such as construction and technical building equipment (TBE) and the authorities. The better and more comprehensive the transfer of expertise from the planning phase to the implementation phase, the smaller the knowledge gaps and project risks during implementation. This applies both to the vertical flow of information from the planning to the implementation phase and to horizontal communication for coordinating the various trades.
Thanks to our guidance, everyone involved in the project knows why, how, by whom and in what order the individual implementation steps are undertaken. This makes collaboration much easier.
Monitoring the execution planning
Once the contract has been awarded, the contracted suppliers begin with the implementation. To this end, they define all the details of the material flow technology in the implementation planning and carry out a simulation. We provide you with intensive support in this phase through close coordination and cooperation with the suppliers as well as continuous monitoring of the suppliers' services to ensure conformity with the planning, tender, offer and contracts.
Early fault detection is the top priority: It is much easier to make adjustments and changes on screen and on paper in good time than it is to carry out complex conversions at the project site at a later date. Among other things, we check the structure and implementation of the simulation, the collision-free nature of the material flow technology with other trades, the ergonomics of the workstations and the safety and accessibility concepts.
Consider interfaces
Special attention should be paid to all interfaces with the construction of the building and the technical building equipment (TBE). Typical areas that need to be considered are the load-bearing capacity of floors, platforms and floor slabs, the power and network connection and, depending on the item, the ventilation, heating and cooling technology.
At the same time, we monitor the planning and implementation of the IT environment. This includes the creation of specifications or the blueprint phase, in which the subsequent processes are finalized, as well as the adaptation and specific programming of the warehouse management systems, material flow computers, PLCs and the interfaces between the various systems and the ERP system.
Constructive solutions for plan changes
Even with careful, forward-looking detailed planning, it is normal that adjustments and changes to the original plans have to be made in the course of implementation planning and implementation. Design requirements may change as a result of new information and findings during implementation. Optimized process sequences or new technologies from manufacturers lead to an improved overall solution once the implementation planning has been carried out.
If changes are required, we take over the change, defect and change request management and initiate the formalized change request procedures. We provide analysis, evaluation, plan adjustments, planning, implementation, monitoring, documentation and communication. Our aim is to constructively support and manage the implementation of logistics. On the way to the best solutions, we also pay attention to commercial aspects such as costs, risks, budgets and economic efficiency.
Accompanying installation
On site at the construction site, we check the agreed qualities for the conveyor and storage technology and test the systems for function, performance, safety and complete documentation. Where necessary, we carry out factory acceptance tests (FAT) or sampling of parts and key components at the manufacturer's premises in advance.
During installation, we ensure that the work is carried out properly. In order to clarify detailed questions quickly and efficiently, we are present on the construction site, accompany and record the installation processes, check the progress of the project and ensure that the milestones defined in the project plan are adhered to.
In the event of delays, we obtain and evaluate compenzation proposals.
Commissioning and ramp-up management
In logistics projects, the commissioning of a logistics system is the most exciting and intensive time for everyone involved. What was initially just an idea is now becoming a reality. The system is brought to life and has to prove itself in practice.
During this critical phase, we ensure that the material flow system can be put into operation at the agreed time and with the required efficiency and evaluate this on the basis of the predefined and firmly agreed success criteria. With careful preparation, a coordinated approach, transparent tests, intensive training and our experience from a large number of projects over the past 50 years.
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Planning ramp-up and commissioning
In preparation for commissioning, we carry out extensive functional, performance and integration tests. To this end, we first validate and check the supplier's tests and ensure that the client's technicians and operators receive qualified training. We define the individual components to be tested and specify the criteria for assessing function and performance. For the integration and mass tests, we prepare test scenarios in accordance with the agreed specifications, define measurement points for the overall system throughput and establish success criteria for the trial operation.
Preparing the commissioning with individual tests
Before commissioning, we check the installation of the conveying, sorting, distribution and storage technology for completeness, quality and accessibility. We then carry out Site Acceptance Tests (SAT), the multi-stage test procedure prepared with data, personnel and materials during the implementation planning and implementation phase.
It starts with performance and function tests, in which we check the individual system components and the providers' control systems for function, throughput, availability and security.
Check integration of material flow systems
This is followed by integration tests of the material flow systems to ensure that they work together smoothly. The individual programmes and programme modules and their interfaces are tested in preparation for connecting the warehouse management system. Their functions and services, documents and dialogues, authorizations and warehouse and material flow strategies are reviewed.
Finally, we carry out a final mass test with test material to ensure that the system achieves a level of performance, availability and operational reliability in trial operation that does not impair the service level. At the same time, we ensure that the technicians and operator receive qualified training.
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Trial operation and ramp-up
The aim of the trial operation and ramp-up is to fine-tune and stabilise the system in live operation so that it delivers its intended performance with a high level of reliability. It processes specific orders under hyper-care conditions. We continuously increase the utilization of the system up to its target values. Weak points are identified and recorded in a list of defects, which we then systematically work through together with the supplier and the operator.
We offer objective escalation management for incidents and disruptions. The future operator will receive further training to familiarise them with the new conveyor and storage technology and the operation of the system. This increases acceptance and ensures a seamless transition of the system from trial operation to regular operation.
Acceptance
Under the real conditions of trial operation, we carry out an early and, after a defined period of time, a final verification of the performance and availability of the overall system.
For the final formal acceptance, all responsible authorities, fire brigades and other institutions must also have given their approval for operation and CE conformity must be ensured. Training and instruction of the operating personnel must be completed and the system must be in a fully cleaned state and ready for unrestricted use. Maintenance and servicing must be ensured with appropriate contractual regulations and spare parts packages.
All documentation and records must be available in full at least two weeks before the acceptance date. Only when all acceptance requirements have been met do we issue an acceptance recommendation.
Accelerated commissioning with the digital twin
Depending on the complexity and degree of automation of the logistics plant, it is worth using a digital twin to shorten the commissioning and ramp-up phase. With a digital image of your system containing all relevant data and simulation models, a series of tests from the commissioning phase can be carried out virtually and thus brought forward to the period in which the system is assembled and installed.
Collisions and conflicts with the building, the operator, among the components or with the goods and materials to be processed quickly become apparent in virtual simulations, operating conditions and scenarios, and unnecessary costs can be avoided through plan adjsutments in good time.
Download our white paper on the topic of the “Digital Twin” here and find out how you can speed up the commissioning of your logistics plant.
References
Our success stories
Logistics Planning
(E-)Commerce & Fashion
Efficient Modernization of Logistics Processes for a Leading Logistics Service Provider with a Wide Range of Article Volumes
General Planning
(E-)Commerce & Fashion
Greenfield E-Commerce Greenfield Fullfillment Center
Anne Köwerich
Business Development Manager
Friedrich-Wilhelm Düsing
Managing Partner
Holger Lorenzen
Managing Partner
Liviu Sotre // CEO and Owner - Lidas SRL