Procedure for the modernization of intralogistics systems

There are system-related reasons for modernizing intralogistics systems, also known as retrofitting, such as declining system availability, rising downtime costs, lack of specialist knowledge about components and system parts, lack of spare parts supply, rising operating costs, safety requirements that can no longer be met, ergonomic and work-related influences, as well as company and market-related reasons.

New requirements on the market can be, for example, changed delivery conditions, changed purchasing behavior, the introduction of new products, new packaging or changed volume flows. New requirements by the company can be, for example, the expansion of production capacity, the improvement of profitability, the optimization and bundling of capacities, a site expansion, relocation or merger and a change in internal logistics. These reasons must be taken into account when planning the new plant and are indicators of which points require particular attention.

Different types of modernization

The types of modernization can also take different forms. For example, the existing system is converted or extended, a new building is added to the existing system or the electronic data processing (EDP) is extended, adapted or renewed. Before a system can be modernized or expanded, every step and every activity must be planned precisely in order to meet the planned deadlines and costs. The following points should generally be taken into account during planning (based on VDI guideline 4403):

1. The first step is to determine the current state via inventory and analysis. Some important points here include The infrastructure of the plant and its surroundings, the material flow and its control, the plant performance and the entire IT system.

2. The next step is to record the requirements based on the planned changes. This describes the target state of the plant. Some important points here are The planned throughput after the modernization, the future range of articles, changes in the material flow and the corresponding adjustments in infrastructure, software and hardware.

3. The conversion or expansion measures required to meet the requirements must be described and documented, taking into account the following aspects: Structural changes, adaptation of warehouse technology, modernization of the IT infrastructure, further training of employees.

4. The risks associated with the conversion, modernization or expansion measures must be identified. These may include the following: A change in the market situation, incorrect assumptions during planning, interface problems with existing technology or missing functions.

5. The requirements, measures and conditions for the planned conversion or expansion are described in the specifications. More detailed information on the preparation of a specification sheet can be found in VDI Guideline 2519 Parts 1 and 2.

6. Next, a schedule must be drawn up in which the chronological sequence of the individual measures and their dependencies are presented. Intermediate dates that are important and decisive for the end date are fixed and documented as milestones in the schedule. Important process steps are the start of the conversion, commissioning, test times and completion of the measures.

7. The final step is the selection of bidders and suppliers, where particular attention should be paid to the references and capacities of the supplier.

Before the conversion work begins, a number of tasks need to be prepared in advance. These include technical and electrical pre-assembly, which will not be explained in detail here, as well as the adaptation and creation of software modules and the training and qualification of personnel.
A detailed description of the above points can be found in VDI guideline 4403.

Further information on modernization can be found under Retrofit in intralogistics.

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