Winora gets new shipping center for European business

The cooperation between the Sennfeld-based bicycle manufacturer, which is now part of the Dutch Accell Group, and the logistics company Schäflein, headquartered in Röthlein, has existed since the 1950s. What began back then with the shipment of individual bicycles is now a highly complex bike logistics operation that is currently facing new, exciting challenges.

Increased space requirements due to rising e-bike sales figures
As the research institute Statista reports, sales of e-bikes in Germany rose from 150,000 units in 2009 to 980,000 in 2018, a trend that is also clearly noticeable at the Winora Group. While the Lower Franconian bicycle manufacturer still handled 80 percent non-e-bikes and 20 percent e-bikes in 2012, the ratio reversed for the first time in 2017. From a logistical point of view, this development meant an explosion in the volume to be stored, as the high-quality e-bikes are packed exclusively in protective full cartons. In addition to the existing, central shipping warehouse for the Winora Group in Röthlein, various other external warehouses were necessary to handle the volume.

These will be brought together in Schäflein AG's new 25,000-square-meter European distribution center, which is expected to be completed in the first quarter of 2020. The logistics company is investing 18 million euros in this. "We believe in our customer and its portfolio. With its modern and innovative products from the WINORA and HAIBIKE brands, the Winora Group always has its finger on the pulse," says Achim Schäflein, Managing Director of Schäflein AG.

Increase to 72,000 bikes
With 11,000 square meters of warehouse space, the Winora Group will occupy over 40 percent of the new multi-user site. A further 4,500 square meters can be added on a variable basis. In figures, this means an increase in maximum storage capacity from 45,000 to 72,000 bikes in the new warehouse, which will be equipped entirely according to the requirements of bike logistics. "Schäflein AG has accompanied us in our growth for decades and, with future-proof logistics, creates the necessary conditions for us to continue to be successful in a rapidly changing competitive environment," explains Dominik Thiele, Regional Director D-A-CH.

20 loading gates to ship over 1'000 bikes more
To ensure short delivery times, Schäflein relies on optimized warehouse logistics with short distances and low replenishment effort: Frequently retrieved items, so-called fast-moving items, are stored in a separate area, B and C items in high-bay warehouses with a picking area at floor level. Induction-guided stackers are used to remove the wheels, always maintaining the optimum distance from the rack so that the order picker can concentrate fully on the picking process. Via 20 loading bays, 2,500 bicycles can be delivered or dispatched daily in the new warehouse instead of the previous 1,400.$

This is how warehouse logistics 4.0 works
The logistics specialists respond to seasonal peaks in the bicycle trade and growth-related changes in volume at the Winora Group with flexible processes and adapted technology. Depending on requirements, the order picker assembles individual orders completely according to the man-to-goods principle or processes several customer orders at the same time by using his forklift to remove items for several customer orders from each compartment. In this system, the actual order compilation does not take place until shipping. Additional scales on the stackers ensure maximum efficiency. In addition, various automation solutions for warehouse logistics 4.0, such as the use of autonomous forklifts and driverless transport systems to supplement manual processes, are already planned during the construction of the hall.

Transparent processes: Shipment tracking possible
From the delivery of the bikes in the warehouse to shipping and the individual transport stations to delivery to the customer - all movements are recorded and converge on a central platform, the Schäflein data cube. If a delivery does not reach certain intermediate checkpoints on time, the logistics specialists recognize the deviations immediately and can take corrective action if necessary. The connected specialist dealer is also informed. The order status of the shipment can be viewed at any time via a mobile web application. In addition, the application offers further services such as a clear order history and user-friendly complaints processing.