Agilon transforms logistics at ABB Smart Power

The primary purpose of the Voyager logistics project at ABB Oy, Smart Power, in Vaasa, was to create a safe environment for high-quality logistics work. With this goal in mind, the unit decided to implement its logistics project. The automated warehouse system Agilon by Konecranes played a crucial role in the project.

ABB Smart Power is a global leader in switch products. Its Vaasa plant manufactures load switches, change-over switches, safety switches, enclosed switches, and switch fuses. Their applications include uninterruptible power supply systems for solar power, backup power, data centres, and industry.

Marcus Mattila, Planning and Fulfillment Specialist, is a logistics expert on the Voyager project at Smart Power: “Early in the project, our project team realized that an Agilon automated warehouse system could benefit us greatly in achieving our goals. The neighbouring unit was using the same system and had a positive user experience. Agilon by Konecranes is a Finnish product, so interaction with the supplier was quick and easy from the outset of planning. The delivery was also quick: the massive piece of equipment was installed in the dispatch department only eight weeks after the order.”

Less chance of error than with the traditional vertical lift system

The differences between Agilon and traditional vertical systems, which Smart Power uses in its production department, include that Agilon supports multiple simultaneous users. "The Agilon system installed here has one loading point and two pickup points. Two pickup robots operate within the system, enabling simultaneous item storage and retrieval or allowing two people to retrieve items simultaneously. Agilon also has a lower risk of errors because only one product type is delivered to the pickup point at a time. Vertical lift systems handle several component types simultaneously, creating a higher risk of pickup mistakes, " Markus says.

Quick installation and smooth implementation

“The Agilon installation took only a few days, and its implementation began with loading in mid-April. The capacity is around 1,300 boxes, and the system now contains 900 boxes. The number of product types is smaller, around 100, because there are multiple boxes of many product types. The number of boxes for a single product type will decrease, allowing us to increase the number of product types. We must load up to 400 product types in this automated system. “If needed in the future, Konecranes can expand the system to meet our needs,” Marcus says.

“We receive most of our distribution products and parts in boxes, which are easy to store in the automated warehouse system. During the project, we relied on Excel to calculate what to keep and how much to keep in our storage facilities. We seek a balance between smooth production, quick deliveries, and optimal inventory value.”

A significant improvement in logistics

"Agilon clarifies processes and material streams, providing much-needed space at our plant. Materials management is more precise and safer than before. We can now trust that the items are in their proper places. When loading the system and picking up items, we run checks to verify the correct products and quantities. Compared with picking up items from shelves, the risk of error is significantly smaller. Safety has also reached a new level now that the system is reducing the need for forklifts. Regarding ergonomics, using Agilon is less burdensome than using a forklift to pick up items,” Marcus says.

“In the beginning, it may seem that loading the system is slowing down reception because only one box at a time is stored in it. However, the time savings will be evident soon in other functions. When an item arrives, we already know where it should be taken. We don´t waste time searching for free space on a pallet, and pickup is faster when most outgoing trading products are available from Agilon at a single pickup point. At this stage, we have used Agilon to trade products distributed to customers through our warehouse.

Ease of use and nonexistent noise

“The people in the dispatch department were a little suspicious at first. They wondered whether adding two pickup points would slow operations and cause congestion, but the system has been very smooth. We can pick up items from Agilon at any time. The dispatch department employees are particularly pleased with how silently the system runs. The pickup robots inside the system are so quiet that sometimes users find themselves doubting whether their pickup request has been processed at all,” Marcus smiles.

“We received Agilon user training via a remote connection. Konecranes provides remote 24/7 support,” the customer says. Of course, the system will become even easier to use when its users gain experience and skills over time. However, it has already proven extremely easy and logical to use. Based on user experiences, we are further developing the system and our operations per our specific needs.”

The system uses fingerprint or password authentication, and the requested product is picked up based on its type identifier. After the product is picked up, the system returns the box to the vicinity of the pickup point, so frequently requested products are gradually placed closer to the pickup point.

The implementation of Agilon has encouraged dispatch employees to consider other improvement ideas related to their jobs and ways of working."

Dispatch Supervisor Jaana Penttala

Dispatch Supervisor Jaana Penttala has noticed that Agilon has also brought about other changes: “The implementation of Agilon has encouraged dispatch employees to consider other improvement ideas related to their jobs and ways of working. Seeing how good ideas inspire people and create a common direction for the team is wonderful. The new workstations still need some fine-tuning, which we expect to complete during the summer. This is also a good opportunity to clean up the dispatch department and remove all unnecessary items from the workstations.”

Marcus says an important step was taken: “Agilon was integrated into our ERP system in connection with an update. This further improved and accelerated the system's operation. The system automatically creates pickup lists. During quieter periods, the system can organize products so that items to be picked up are as close to the pickup point as possible. This will ensure a quick pick up the next day.”