The Dutch production and distribution site of Evonik Colortrend in Maastricht produces liquid colour pastes for paint and coatings producers worldwide.
Each paint consists of several colour pigments, liquid or powdered, which are mixed according to a recipe. When producing large batches of colour paste, weight differences occur. Within a certain tolerance, small weight differences in the ingredients have no considerable influence on the final result, but in the long term, these differences have a large impact on stock control, and therefore on cost levels. Evonik searched for a way to manage stocks and consumption, both in storage and in production.
Investment in hardware and software
To achieve the intended results, Evonik has invested in two reach trucks with truck terminals and RAVAS iForks.
iForks make stock differences immediately visible
How does it work?
A customer orders 100 kilos of a certain colour paste. According to the recipe, three different raw materials and pigments are needed for production. The WMS/SAP shows that all the required raw materials are in stock. Via his truck terminal, the reach truck driver has a wireless connection with the WMS. Guided by a pick order on his truck terminal, he picks the required raw materials with the reach truck. At the same moment the picked materials are weighed via iForks and the driver visually compares the real weight with the stock level in the WMS. If the weight corresponds with the theoretical stock level, the load is taken to the batching area. If the driver observes a stock difference, he enters the correct weight into the WMS. The remainder coming back from production is returned to the warehouse where it is once again weighed.
Roland Doorenbosch, Manager Maintenance & Engineering
"This weighing method works much faster than balancing and cycle-counting. In iForks, Evonik found an inexpensive, simple and easy to implement way of controlling stocks."
About the application
With global supply chains that stretch across continents, with small stocks and just-in-time deliveries, companies have become very vulnerable to stock shortages. Shortages mean interrupted production processes, delays, loss of customer confidence. And they all come with a cost. With a mobile scale, connected to your ERP or WMS system, material flows can be monitored every time goods are moved: inbound goods, goods in and out of production, outbound goods. Without interrupting the process, mobile scales allow you to accurately control your stock, reduce stock levels and lower cost.Read more about stock control