Warehouse Controls Upgrade

The client's need:

Karmax's metal stamping operation had a high-rise warehouse for storing automotive body components produced on four press lines. Parts were conveyed by AGV to the seven-aisle warehouse where they were automatically stored by the automatic storage and retrieval cranes. Daily operation consisted of manufacturing parts on the metal stamping lines, storing them and retrieving parts from the warehouse to fill orders.

The client wished to replace aging control systems for the AGVs, storage and retrieval cranes and other related material handling equipment with state-of-the-art technology. However, when replacing the control systems, only one press line and two aisles of the warehouse could be taken out of service at one time. The production schedule only allowed for partial shut down during the last three weeks of December.

Karmax required the new system to operate, both physically and operationally, in parallel with the old system so changeover would be seamless.

How CSI solved the client's problem:

CSI developed a modular control system, permitting the client to continue normal operations during every step of the installation by preserving the communication with the warehouse's legacy computer.

This phased approach allowed CSI's engineers to convert from the old system to the new one, aisle by aisle, while always maintaining production in three lines and five aisles.

When the time came, we simply switched over to the new system without any interruptions.