Schönenberger Systeme
 
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R.O.I. for Schönenberger users

Based on your today's performance for factors like
current production times, range of articles, local costs and machinery and technology used today,
a revised and updated material management system from Schönenberger can show short r.o.i. terms;
in special cases even within months.


Potential savings in apparel manufacturing

Case Studies - process management Case Studies - dynamic storage and warehousing
· Trousers in Portugal · Shirtmaker with streamlined processes
· Ladies wear in Slovenia · Using the cube revitalizing existing buildings
· Men's trousers in Italy · Dynamic storage for production … under the roof
· Brides robes in Italy · World wide logistic for spare parts
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World wide logistic for spare parts

Worldwide supply of spare parts

600,000 orderlines and 124,000 deliveries are to be processed by the bavarian company. Permanent access to 25,000 spare parts and 800 new gear is requested.

Optimizing the processes demanded standardization of processing, cutting off throughput time and enhance the quality of delivery. Where before hand carts were manually operated today special customized trolleys drive mostly automated on 620m of transport and buffer rails.

Different warehouse areas are reached by 12 "stations" in different warehouse levels.

The trolleys with individual set codebars are transported automatically from input to drop-off along optimized routes.

The trolleys can be loaded with up to 60kg.

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Brides robes in Italy

Complex assembly of bride robes
Visions in white - tailor made.

The SCHÖNENBERGER system serves the production plant throughout from cutting to assembly which is arranged in several groups.
The flexible 3-line-principle for hanging production connects all groups.
After assembly the fancy robes are taken to ironing and finishing, bagging and further to the dynamic storage.
The production area covers 3 levels connected by elevator.

"Our bride robes are quite complex to produce.
300 - 1,100 minutes per robe, a high variety of styles, excellent manufacturing and delicate materials like silk, satin and lace.
Nearly every piece is tailor made and processing time is highly relevant.
At first, we opposed the idea of hanging production.
But after implementation, launch and extensive systematic training by SCHÖNENBERGER consultants we are now real fans of this innovative technology.
Our initial concerns towards the reorganisation was for no reason.
Today everything runs like clockwork."

World wide logistic for spare parts

Worldwide supply of spare parts

600,000 orderlines and 124,000 deliveries are to be processed by the bavarian company. Permanent access to 25,000 spare parts and 800 new gear is requested.

Optimizing the processes demanded standardization of processing, cutting off throughput time and enhance the quality of delivery. Where before hand carts were manually operated today special customized trolleys drive mostly automated on 620m of transport and buffer rails.

Differend warehouse areas are reached by 12 "stations" in different warehouse levels.

The trolleys with individual set codebars are transported automatically from input to drop-off along optimized routes. The trolleys can be loaded with up to 60kg.

Ladies wear in Slovenia

30% increase in production within short period

Installation of the SCHÖNENBERGER system with 3-line-principle for
29 workstations for trousers- and 72 worstations for jacket assembly.
Using C-bundle-trolleys pants, blouses, skirts and coats can be produced.

"First we used the SCHÖNENBERGER system just for the trousers group with 29 workstations. By changing to hanging production we could increase the production soon up to 30% - with unchanged set-up of machines .
So we began to review our jacket assembly. Few months after altering the trousers produciton we also changed the jacket production to hanging. Today we transport everything hanging and have a thorough overview."



Pay-Back-Calculation

Shop Logistics - extreme requirements

Keep things moving…

Contract and shop logistics support retailers. The supply chain is formed by a number of individual steps.

SCHÖNENBERGER systems support a seamless flow: from input, QC, putting on hangers, ticketing, finishing, storage, packing until dispatch.

On time ... at the point of sale !
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!!! Case Study
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e-commerce following mail order business and spare parts logistic

Good – better – Schönenberger

Actually logistic services for e-commerce, mail order and spare parts supply ask for magic wand waving:
Thousands and hundred-thousands of different items are stored, picked, sorted, packed and shipped in cycles tuned to seconds.

"Oops … here you are" - the smallest size, the weirdest colour for the finest customer."

For SCHÖNENBERGER systems love to engage with such challenges - successfully.
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!!! Case Study
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Shirtmaker with streamlined processes

Long established company for apparel

The volume of orders for the company increases ever year. About 5,000 retailers worldwide buy roundabout 3.5 Mio. shirts and 500,000 blouses per year.

The warehouse capacity shall be optimized with an unchanged number of operators. The processing was re-designed and a Schönenberger system for all 3 storage levels implemented.

The warehouse was restructured integrating further areas. The result is a better overview, faster processing with improved material flow. The product range is manifold / various / multiple: Bagged blouses and shirts partly in carton boxes partly hanging are ready for call off in a customer oriented distribution centre: Customers in Germany and Austria get their orders within 24 hours - the rest of Europe within 48 hours.

The considerable alterations were implemented during ongoing operations.

Distribution

Out with it!

Within the supply chain this is the key to "distribution":
to know well before the merchandise comes into the warehouse how many items need to get to their point of sale - and when.

E-commerce is the progression: orders fly in round the clock and need to be processed as fast as possible and correct down to the very last order line.

Like a boomerang many of the shipped goods will presumably come back as returns. The challenge of this event-driven-logistics (e-log) is to handle each item individually.

The answer to this is:
the best logistic solution involves the least effort.
Processes can run highly automated with manual operations where appropriate.

Warehouse

Calm Movements

SCHÖNENBERGER understands "storage" as a kind of stand-still transport in a workflow. Thus SCHÖNENBERGER tends to design "storage" as a dynamic, continuous process from raw material storage to the point of sale.
Planning includes the use of full building capacity in width, length AND height! If necessary to the remotest corner.
Thus the sotrage capacity can be enhhanced and sometimes building new can be spared.  > read more  
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!!! Case Study
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R.O.I. :

Schönenberger hanging production system for men's trousers.

Company data:
production time/trouser: 36,2 min
Qty/day before implementation of Schönenberger: 610 pcs.
Costs/operator
(taken in 2009):            
4320 €/month
20 workdays/month
= 216 €/day (8hr/day)
= 27 €/hr
R.O.I. :
We experienced a reduction of ca. 20% in assembly time with the Schönenberger system. I.e. : 20% of 36,2min = ./. 7,2 min./trouser.

7,2 min/trouser x 610 pcs./day = 4.392 min/day
= 73,2 hr/day = 1.976,4 €/day saving.

Invest for Schönenbeger system for 73 sewing stations: ca.140.000 €
140.000 € : 1.976,4 € = 70,8 work days saved

R.O.I. = 4 months (at 220 workdays/year)

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Dynamic storage for production …
under the roof

Manufacturer of fittings and big parts

The alternative options were: either a new building
or optimize the use of the existing buidling.
The customer was keen to consider alternative technologies.

The suprising result was to use the shed space of the production building.
Along 2 buffer circles and vertical conveyor the parts on barcoded single carriers are stored, sorted and are taken to production by call.
e-log = event driven logistic: every barcoded trolley is unique.

This unconventional solution saved half of the originally budgeted investment.

Warehouse Capacity

Mens Wear Manufacturer in Southwest Germany

The company produces annually around 800,000 GOH (singles) with a 60% export rate.

Supported by SCHÖNENBERGER logistic technology and know-how the company today benefits from
improved quality, enhanced flexibility, reduced costs.

In their 15.000 sqm and 3-level warehouse about 500,000 GOH are stored, 700 parcels and 5,000 GOH per day are shipped.
Same day shipment for orders received before noon is ensured.
Storage capacity can be increased by 50% upon demand.

Men's trousers in Italy

3 weeks reorganisation - and all works just fine.

There are 274 workstations all over the production.
The "throughout" concepted SCHÖNENBERGER system starts with putting cut pieces from cutting tables onto 4-level tray gondolas. After labelling and further worksteps in pre-assembly area, the trousers are pneumatically clamped - in bundles of 10 - on trolleys for assembly.

After pressing and QC the ready trousers are taken to a dynamic storage over 2 levels connected by reversible in-/decline conveyor. Adding trapeze bars to the trolley provides 4 hanging levels for trousers and the optimal use of the available space.

"With SCHÖNENBERGER we planned to increase our production from 2,000 to 2.400 trousers per day, meaning 20%. Soon we achieved 2,700 trousers per day rising in peaks up to even 3,000 per day. This means a rise in productivity of up to 50%.
Amazing! And most welcome."


Pay-Back-Calculation

Mail Order

One of Europe's biggest Mail Order Companies for software, computer accessories and lifestyle products

More than 14,000 different articles and more than 20,000 parcels per day are shipped. With SCHÖNENBERGER an excellent grade of mechanization was achieved: the company can now handle capacity leaps and achieved a rise in daily performance.
With a hanging transport system in the high bay storage together the available room was used in full dimension and the existing storage system was incorporated to serve the new one.
All operational areas in the new and existing parts of the building were conneted by horizontal and gravity conveyors transporting 300 trolleys with 1.5 cbm capacity and 80kg loaded weight. The result was a picking system with high fault tolerance. The main role of the operators at picking and identification of the items was highly taken into account and incorporated within the overall material flow.
Trousers in Portugal

Considerable cutback in processing time.

At 73 wokstaions 45 operators produce elaborate high quality trousers. The SCHÖNENBERGER 3-line-principle for hanging production connects sewing and ironing workstations. As the long parts of the trousers are not to touch the floor the workstations are put onto platforms.

Using pneumatically operated clamp in- and -out stations trolleys can be charged and discharged fast and easyly. The bundles are secured on the trolleys and the cut pieces cannot fall down.

"We have reduced the bundle size from 20-25 trousers down to 10. Using the Schönenberger KBT bundle clamp trolley for trousers we can work in waterfall mode. Thus we save up to 40% handling time and have a clear view over the assembly area. The SCHÖNENBERGER system helped us to remarkably reduce our processing time."


Pay-Back-Calculation

R.O.I. :

Schönenberger hanging production system for men's trousers.

Company data:
production time/trouser: 40 - 50 min
Qty/day before implementation of Schönenberger: 2.000 pcs
Costs/operator
(taken in 2009):      
1.600 €/month
20 workdays/month
= 80 €/day (8hr/day)
= 10 €/hr
R.O.I. :
We experienced a reduction of ca. 20% in assembly time with the
Schönenberger system. I.e.: 20% of 40-50 min = ./. 8 - 10 min./trouser.

8-10 min/trouser x 2.000 pcs./day = 16-20.000 min/day
= 267-333 hr/day = 2.670 - 3.330 €/day saving.

Invest for Schönenbeger system for 274 sewing stations: ca. 420.000 €
420.000 € : 2.670-3.330 € = 126 - 157 work days saved

R.O.I. = 7-8 months (at 220 workdays/year)

Using the cube revitalizing existing buildings

Renowned company through the ages / in changing times…

The company founded 175 years ago change their production structures thoroughly.

From fully integrated textile company that produced everything from yarn to finished clothing the company today has developed into a progressively run company with a central distibution centre.

Several areas in different building levels - sometimes more than 150m apart - were efficiently connected and equipped with a SCHÖNENBERGER transporting system.

The extensive product range is processed flat and hanging. Every year more than 350 shops and 3,500 retailers are supplied by the central distribution centre.

Dynamic storage for production …
under the roof

Manufacturer of fittings and big parts

The alternative options were: either a new building
or optimize the use of the existing buidling.
The customer was keen to consider alternative technologies.

The suprising result was to use the shed space of the production building.
Along 2 buffer circles and vertical conveyor the parts on barcoded single carriers are stored, sorted and are taken to production by call.
e-log = event driven logistic: every barcoded trolley is unique.

This unconventional solution saved half of the originally budgeted investment.

World wide logistic for spare parts

Worldwide supply of spare parts

600,000 orderlines and 124,000 deliveries are to be processed by the bavarian company. Permanent access to 25,000 spare parts and 800 new gear is requested.

Optimizing the processes demanded standardization of processing, cutting off throughput time and enhance the quality of delivery. Where before hand carts were manually operated today special customized trolleys drive mostly automated on 620m of transport and buffer rails.

Differend warehouse areas are reached by 12 "stations" in different warehouse levels.

The trolleys with individual set codebars are transported automatically from input to drop-off along optimized routes. The trolleys can be loaded with up to 60kg.

Individual Codes for Product Groups

Intra Logistic System SCHÖNENBERGER ILS 2100

The supply chain stretches out: global supply and shops around the world are the challenge.
The newly developed Intra Logistic System SCHÖNENBERGER ILS 2100 covers most of the processes in distribution- and logistic centres.
Shop replenishment runs either daily or weekly.
Optimized floor management, intensive control of returns and high transparency in the distribution centres do essentially enhance supply service.
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under construction

 
under construction

 
Using the cube revitalizing existing buildings

Renowned company through the ages / in changing times…

The company founded 175 years ago change their production structures thoroughly.

From fully integrated textile company that produced everything from yarn until the finished clothing today it's a progressively run company with a central distibution centre.

Several areas in different building levels - sometimes more than 150m apart - were efficiently connected and equipped with a Schönenberger transporting system.

The extensive product range is processed flat and hanging. Every year more than 350 shops and 3,500 retailers are supplied by the central distribution centre.

R.O.I.:

Schönenberger hanging production system for ladies' trousers.

Company data:
production time/trouser: 61 Min
Qty/day before implementation of Schönenberger:  150 pcs.
Costs/operator
(taken in 2009):             
2080€/month
20 workdays/month
= 104 €/day (8hr/day)
= 13 €/hr
R.O.I. :
We experienced a reduction of ca. 20% in assembly time with the
Schönenberger system. I.e. : 20% of 61min = ./. 12,2 min./trouser.

12,2 min/trouser x 150 pcs./day = 1.830 min/day = 30,5 hr/day
= 396,5 €/day saving.

Invest for Schönenbeger system for 28 sewing stations: ca.56.000 €
56.000 € : 396,5€ = 141 work days saved

R.O.I. = 7,7 months (at 220 workdays/year)