Agilon streamlines Demag hoist assembly with 90% availability and 95% faster picking

Demag Cranes & Components GmbH, a global leader in industrial cranes and drive solutions, faced a common challenge at its Wetter, Germany site: managing complex material flows in a configure-to-order crane environment. Demag also produces stock hoists—most custom-configured—adding significant complexity to parts management, storage, and material flow. 

Each hoist is assembled from 75 to 130 unique components and now Konecranes’ advanced, field-proven warehouse automation system efficiently picks 20-50 of these small parts per hoist, boosting both speed and accuracy.

CHALLENGE

Overcoming picking inefficiencies and storage limits

Before implementing warehouse automation, Demag faced storage constraints, slow picking processes, and frequent errors that delayed production. On-site material availability met only 60% of production orders, resulting in delays, manual picking errors, and bottlenecks during the final assembly process.

SOLUTION

Warehouse automation and high-bay supermarket

Agilon was selected following a thorough evaluation of Demag’s specific needs. Konecranes supported this with detailed calculations for informed decision-making. After an objective procurement process, Agilon stood out for its most effective and future-ready features.

Demag combined a high-bay supermarket for palletised goods with Agilon to manage high-volume small parts, resulting in significantly improved warehouse efficiency and faster production responsiveness.

RESULTS

Dramatic improvements in speed, accuracy, and availability

90% on-site availability of small parts
Automated storage and retrieval capabilities, working in conjunction with the high-bay supermarket, have reduced reliance on the central warehouse. Now, 90% of the required materials are available directly on-site, streamlining production.
Before Agilon: 60%  After Agilon: 90%

95% faster small-part picking
Thanks to Agilon’s batch picking, pick-to-light, and flow rack support, along with SAP ERP integration, picking time dropped from 12 minutes to 30 seconds per order. Operators now prepare 7–10 production orders per batch, significantly increasing throughput.
Before Agilon: 12 minutes  After Agilon: 30 seconds

Higher accuracy, quality, and ergonomics
By automating the picking process and integrating quick-order parts into a unified workflow, Agilon reduces errors, enhances hoist quality, and improves operator ergonomics at access points.

Flexibility and scalability for the future
Agilon’s modular design and scalability allow Demag to adapt the system as production needs grow.

CONCLUSION

Agilon enables agile, scalable and efficient production

Agilon has effectively resolved Demag’s storage and picking challenges, delivering a scalable solution that supports growth, enhances product quality and efficiency, and boosts customer satisfaction.

Efficiency, accuracy and capacity
At the heart of Demag’s production strategy, the 40-meter-long Agilon system features five user access points and a total capacity of up to 1,638 boxes. The system delivers measurable improvements in efficiency, accuracy, speed, and workplace safety:

• Up to 2,500 pick lines per shift
• 570 different materials in stock
• 75–130 components per hoist per production order
• 20–50 small parts per unit picked via Agilon
• Over 1,100 active storage boxes in daily use
• On-site small-parts availability increased from 60% to 90%
• Small-part picking time reduced from 12 minutes to 30 seconds per order
• Shorter lead times and improved delivery reliability
• Enhanced ergonomics and reduced internal logistics traffic

LOOKING AHEAD

Scalability and continuous improvement

Agilon’s role at Demag continues to evolve. As production needs evolve, the system supports ongoing development through the introduction of new features and targeted enhancements. If the number of pick lines continues to grow, and once the warehouse reaches full ramp-up, both picking speed and volume are expected to double, further enhancing efficiency, responsiveness, and competitive advantage.

Integration of new functions, such as inbound and outbound conveyors, conveyor belts, the Agilon Autoload Trolley, and AGV and AMR solutions, can be easily implemented as production needs evolve.