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However, this logistics strategy began to approach its limits. One specific challenge resulted from the different categories of products that had to be handled. The products can be categorized as slow or fast movers. Fast movers are products that are sent out to retailers in large volumes during a short period of time and move rapidly through the logistics process. The so-called slow movers, in contrast, such as high-value or exclusive models, are handled in lower volumes but remain in the warehouse for a longer period of time. To make things even more complex, a product can change from a slow to a fast mover, or vice versa, depending on its lifecycle status. Both categories were being handled within the same warehouse, and this posed a significant obstacle to increasing product

After completing the modernization of a main sorter unit, Samsonite in Belgium implemented a PROFINET-based automation solution with safety and wireless technology in a brand-new logistics center.

For almost a century, Samsonite has proven itself to be the worldwide leader in innovative travel solutions. Thecompany’s European headquarters in Oudenaarde, Belgium, also form the logistics center for Europe. In recent years, Samsonite’s product line has become significantly more diverse, which has created logistical challenges. In order to deal with the growing product portfolio, external warehouses were used in the logistics chain.

Samsonite chooses PROFINET – again!

PROFINET

www.siemens.com/profinet

Content

p.1 Samsonite chooses PROFINET – again!

p.3 Fewer errors, higher volume: The soft-goods sorter project

The new “slow movers” warehouse: A sophisticated automation solution with integrated safety technology allows parallel operation of manned and automated guided vehicles

Safety Integrated ensures operational safety: SIMATIC light grids and other safety sensors connected through SIMATIC ET 200S protect hazardous areas in the “slow movers” warehouse

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diversity and containing logistics costs. Consequently, Samsonite decided to build a new, dedicated warehouse for slow movers, with space for 11,000 pallets, to optimize the cost structure as well as the logistical capacity, efficiency and flexibility.

A challenge for logistics and automation technology

Samsonite wanted the new warehouse to be semiautonomous, with no need for fixed staff. An elaborate safety system was also required, as staff, one manned forklift, and automated guided vehicles (AGVs) would be moving at the same time in the warehouse. Consequently, Samsonite needed an automaton and communication solution that could incorporate wireless communication and safety features. With PROFINET, also wireless, and Safety Integrated, Siemens is the unique provider of such an integrated solution in a wireless environment.

Integrated safety technology protects equipment and personnel

This warehouse project builds on the trust PROFINET and Siemens earned on a previous automation project, completed in summer 2007, in which a new sorter multiplied capacity for the growing soft-goods portfolio. In the slow-movers warehouse, a fail-safe SIMATIC S7-319F CPU communicates with the automation systems in the field via PROFINET and Industrial Wireless LAN. Multiple SCALANCE W access points enable wireless connection to the AGVs, which are all equipped with SIMATIC ET 200S distributed devices with fail-safe CPUs. The control room is equipped with a SIMATIC PC 577 with SIMATIC WinCC flexible for monitoring. The signals in the field are connected via SIMATIC ET 200S with standard and safety I/Os. SIMATIC light grids protect hazardous areas. PROFINET also connects SCALANCE X industrial switches and several IP cameras. The IP cameras enable monitoring critical

points in the logistics chain and can be checked quickly with WinCC flexible. A wireless failsafe SIMATIC Mobile Panel 277F IWLAN is used for flexible on-site operation.

The new warehouse was commissioned in July 2009 and now handles the logistics for slow-mover products for the European market. External warehouses are no longer required. By integrating automation and safety tasks into one uniform architecture based on PROFINET and incorporating both wired and wireless communication, Samsonite can now operate the new warehouse without having to allocate permanent staff. During peak times, when AGVs and operators are working together, Safety Integrated reliably protects both equipment and personnel. Samsonite can now react quickly and flexibly to changing demand from retailers while optimizing logistics capacity and cost.

The automation configuration in the new “slow movers” warehouse In the “slow movers” warehouse, high-performance SCALANCE access points with rapid roaming integrate the automated guided vehicles into the PROFINET network

AGV

AGV

PRO

FIN

ET

Indu

stri

al E

ther

net

Conveyor

Con

veyo

r

SIMATIC Mobile Panel277F IWLAN

SIMATICFS400

PROFINET

Industrial Ethernet

SIMATICPC 577

withWinCC

flexible

SCALANCEX200

SCALANCEAccess Point

SCALANCEX200

SCALANCEClient

SCALANCEClient

SCALANCEAccess Point

SCALANCEAccess Point

SCALANCEX200

SIMATICS7-300F

SIMATICET 200S

SIMATICET 200S

SIMATIC ET 200S

SIMATICET 200S

SIMATICET 200S

SIMATIC Microbox PCOperator registration

Traffic controlSIMATIC Microbox PC

Central cabinet

Pickzone

Logistic zone (200 m)1

Logistic zone (200 m)6

Other equipment:12 IP cameras connected to PROFINET network36 Siemens light barriers / each logistic zone has 6

Control room

LAN

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Just half a year prior to beginning work on the slow-mover warehouse, Siemens implemented an automation solution for a new sorter that also uses PROFINET as the communication backbone. The sorter has improved the logistics for the soft goods market. This market has been growing rapidly in recent years, leading to an enormous increase in the diversity and volume of products that need to be packed and shipped for European markets at the logistics center in Belgium. Consequently, the center was approaching its limits for handling these products in 2007.

Integration into existing infrastructure

When Samsonite involved Siemens for the automation part of the project, the

project team faced several challenges. In just five months, the previously manual sorting had to be transferred to an automatic sorter. This 109-meter-long new sorter had to be built into the existing infrastructure. The automation systems had to be distributed along the sorter as well as the in- and outbound conveyors. Moreover, cabinet space was very limited, so the automation solution had to be very compact, preferably with cabinetless design where possible. Samsonite also required that the system be able to be switched into manual mode at any time should the logistics process require it. With PROFINET as the communication backbone and SIMATIC automation technology, Siemens was able to meet all these requirements. The new split-tray

Fewer errors, higher volume: The soft-goods sorter project

The new sorter, fully automated and based on PROFINET, has significantly improved capacity and process quality – watch the video of the sorter: www.siemens.com/profinet.

The dedicated “slow mover” warehouse exploits the benefits of PROFINET, also wireless and Safety Integrated – watch the video of the new logistics center: www.siemens.com/profinet.

For both Samsonite projects is a video available.

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sorter with 318 trays achieves a speed of goods of 0.8 meters per second on the conveyor line. The programmable logic controller (PLC), I/O devices, HMI, Industrial PCs, and IP cameras are all connected to the PROFINET network. The automation sequences are run from a SIMATIC S7 CPU 319-3 PN/DP, while SINAMICS drives and MOTOX geared motors are used to synchronize the split-tray sorter with the conveyors. SIMATIC ET 200pro with motor starters were installed without cabinets in the field, helping save on valuable cabinet space.

Future-proof solution with excellent performance

Thanks to the integrated and uniform architecture with PROFINET communication, the system was commissioned in record time. The powerful diagnostic features available over PROFINET ensure rapid troubleshooting and high system availability. With PROFINET and SIMATIC technology, Samsonite not only opted for an open solution that is capable of adapting to future requirements, but

also was able to immediately reap the benefits of an automated sorting process. Productivity increased by more than 30 percent, and the solution will provide a return on investment in less than two years. The new sorter has doubled the logistical capacity of the warehouse, with all new systems implemented in the existing building. The new process is also much more reliable: the error rate has dropped by factor of 10, to almost 0.

The automation configuration in the sorter

Left: In the sorter, Siemens implemented a distributed automation solution based on PROFINET communication that offers flexible local operation and monitoring options while minimizing required cabinet space Right: The sorter benefits from installation options that don not require an electrical cabinet with distributed SIMATIC ET 200pro with motorstarters that can be installed almost anywhere on the sorter line