Swisslog builds IKEA's future Customer Distribution Centres

In March 2003 IKEA opens a German Customer Distribution Centre (CDC) in Dortmund. Those who use the Internet to order, or who cannot take the goods home from the furnishing store themselves, can have almost everything – from “Hemlis” clothes hangers to a complete “Faktum” kitchen – delivered to their house. SICK sensors will ensure the smooth functioning of warehouse and commissioning plants at the CDC.

>> Every year millions of young or still young customers discover witty ways of living and smart furnishing details in IKEA stores. But despite all IKEA’s efforts to make one’s outing comfortable, not every potential customer can or wants to take the time to visit the furnishing store. Many of them would rather surf the Internet for “Barken” towels or a set of “Marion” sheets. And while many appreciate the contents of the flat IKEA packages some do not want to have to transport them themselves.

IKEA comes to the customer

In response to this customer trend, IKEA has already opened a CDC in Jönköping, Sweden – in spring, 2002. This logistical centre, set up by the company Swisslog and its subcontractor Accalon, is designed to handle over 4,000 articles, 190,000 picking orders and 18,000 deliveries a day to end customers. This is made possible by using a system that automatically rearranges the pallets according to the customers’ demands.

“Dynamic picking locations are the keywords in the IKEA CDC warehouse”, says Nils Huss, Project Manager at Accalon. “The same picking location can be used for more than one article. With a powerful Warehouse Management Software and with ultra-fast cranes the articles can be transported to the picking locations faster than ever before.”

Swisslog, leading in Supply Chain Solutions is assigned to deliver the new distribution centres in Sweden and Germany, including its WMS. Accalon, a Swedish automated materials handling company, provides the centre with the conveyor system and cranes. After 25 years in business, Accalon is now one of the leading actors in Europe with a crane program that is first class in function and modularity.

IKEA-blue sensors

Blue as IKEA’s printing, SICK sensors provide a wide variety of operating information to the plant control systems in Jönköping and Dortmund. MLG Modular Light Grids detect whether any parts are jutting out into the path to hinder the movement of the load-bearing fork of any high-bay stackers.

DS 60 Distance Sensors check the current occupancy of the double-depth warehouse shelves. Thanks to the two separate switching outputs, the device can also distinguish a pallet loaded at the front from one at the back. The DME 3000 laser distance measurement system determines the current position of a high-bay stacker along its route. Their high levels of precision ensure the vehicle stops with millimetre accuracy in the 100-metre-long aisles. Furthermore, countless blue photoelectric switches are employed on the roller conveyor systems or at the contour-checking stations.