ABB DS boosts final assembly efficiency by 30–40% with Agilon warehouse automation

Maximizing capacity and efficiency with Agilon

The ABB Distribution Solutions unit (ABB DS) in Vaasa manufactures automation protection relays to safeguard medium-voltage networks and their devices. These products make power grids smarter, more automated, and safer.

"Our products are an important part of the switchgear systems in both ABB's factories and those of other equipment manufacturers," explains Production Manager Petri Kleimola.

Kleimola and Production Supervisor Sami Vesavuori are responsible for developing the production unit. One of their critical projects involved implementing and customising the Konecranes Agilon automated warehouse to suit their needs. This development work has significantly improved production efficiency, functionality, and occupational safety.

ABB DS required an efficient, space-saving automated storage solution due to limited storage space. Critical selection criteria included ease of use and fast support in case of issues, as downtime could halt production.

"We found Konecranes' Agilon solution, compared it with other options, and received positive feedback. The system was the best fit for our needs, so we decided to invest," Kleimola explains.

Achieving growth by scaling and expanding Agilon system

ABB DS implemented the Agilon system in 2019. As production volumes and storage needs increased, the system was expanded and updated with new functionalities. The current system, measuring 28 meters in length and 6.1 meters in height, has four user access points.

Agilon stores parts required for production orders, including cables and other necessary components. Components are stored in Agilon in their original packaging. With 99% of production components fitting into the system, we store only a few oversized products we store elsewhere.

Agilon efficiently stores essential production components, such as cables and additional parts, in their original packaging. Ninety-nine per cent of production materials fit into the system, and only a few oversized items are stored separately.

As production scaled, Agilon's flexibility enabled ABB to replace space-consuming pallet storage, optimizing the layout for greater efficiency.

"We expanded Agilon to utilize space more effectively, eliminating the pallet warehouse and transferring items to the upgraded system. This reorganization freed up valuable floor space for production, greatly enhancing space efficiency," Kleimola adds.

Optimizing picking efficiency with automation

To improve the picking process and speed up material collection, Konecranes suggested features such as pre-picking, parallel picking, and batch picking. As part of the development project, Agilon was integrated with the SAP Enterprise Resource Planning (ERP) system, enabling comprehensive management of the production warehouse.

Parallel picking enables the robot to efficiently deliver boxes to adjacent access points in the specified order.

Batch picking enables the simultaneous picking of multiple orders, thereby accelerating the overall process.

Anticipating future picking orders greatly enhanced operational efficiency. Sami Vesavuori explains, "A new job role was established to train and develop team members into experts."

Pickers work in shifts, selecting required production orders from SAP. Agilon retrieves the necessary components and provides light guidance to ensure accurate picking. Once the picking is complete, the picker instructs the Omron mobile robot to deliver the orders to the production line.

Previously, the final assembly team collected components from multiple warehouse locations. Now, materials arrive directly at their workstations, significantly accelerating the process.

Ergonomic light-guided picking tables for enhanced efficiency

When Vesavuori discovered Konecranes' new light-guided Agilon picking cart, he proposed customizing the shelves and adding an ergonomic picking table to enhance production efficiency and worker comfort.

"We proposed a picking table instead of the cart, featuring eight picking boxes to hold two assemblies each," he recalls.

This suggestion was quickly integrated into the Agilon product development, adding new functionality that boosted production efficiency and enhanced employee safety.

Measuring and improving efficiency

According to Vesavuori, ABB regularly conducts time measurements to assess the improvements in picking processes. "The measurements help us focus on the right areas for development."

These improvements have had a significant impact on production, with time studies showing that picking efficiency in the final assembly has improved by 30–40%. The following development targets will focus on the pre-assembly process.

Agilon's integration, automation, and robotics have also minimized human errors in the picking process. Barcodes ensure reliability and accuracy, and robots deliver materials directly to the production line.

Vesavuori emphasizes that Agilon dramatically reduces picking errors, guaranteeing that customers receive the right products. "Agilon ensures we virtually eliminate mistakes, leading to higher customer satisfaction," he says.

Streamlined inventory process

Agilon streamlined ABB DS's annual inventory process. Production no longer needs to stop for inventory counts, and balance monitoring is reliable.

"Before Agilon, the annual inventory could take up to two days. With Agilon, we've cut that time significantly, saving hours and improving overall accuracy," says Vesavuori.

The inventory process is now handled directly through Agilon's portal, further simplifying the task.

Production employees at ABB DS are enthusiastic about adopting new functionalities and actively contributing ideas to improve Agilon's performance. "We've received many valuable suggestions from users, which we pass on to Konecranes," explain Kleimola and Vesavuori.

Initially, the system had one robot, but as production volumes increased, a second was added. A third robot will prevent bottlenecks as production expands.

"Collaboration with Konecranes is easy. They understand our processes and needs, making development and implementation smooth and efficient," Vesavuori concludes.

Customer-driven solution

Teemu Oittinen, Solution Sales Director of Agilon, values the feedback from ABB DS and other customers. "Customer-driven development is the key to the evolution of the Agilon warehouse management system."

Why ABB chose Agilon: "We needed a storage solution that could help us optimize space while being flexible enough to handle increasing production volumes. Konecranes Agilon stood out as the best fit for our needs,offering scalability, ease of use, and excellent customer support. It’s been a game-changer for us."

Petri Kleimola, Production Manager, ABB Distribution Solutions

New functionalities, such as the ABB-conceived picking table and the new Agilon conveyor, are now available to all Agilon customers, showcasing how customer feedback shapes the future of warehouse management.

Key Agilon outcomes at ABB DS

• Scalable and adaptable warehouse automation solutions
• Optimised space efficiency and operational flexibility
• Increased efficiency and reduced errors in production
• Enhanced workplace safety and streamlined workflows
• Collaboration is driving new functionalities and customer satisfaction