Cartiere del Garda – Logistics of paper, LOGISTICS OF GIANTS

logo cartiere gardaLogistics use the philosophy of Formula One pit stop to organize the revamping of an automatic warehouse in a few days and without stop manufacturing operations.

This is the case of Cartiere del Garda, a supply chain of coated paper. Working without stop 365 days a year, with a delicate product such as paper, it could not afford either to block the production cycle for too long, nor to empty the automatic warehouse. So, basically, everything had to be done “in the running”. The choice of doing a kind of open-heart surgery during a technical stop in August, during which an interruoption of the production cycle, if expected as Swiss precision, would not create too many problems.

Cartiere_del_GardaMoreover, the alternatives were not so much. Cartiere del Garda had to remedy the limitations of an automatic plant outdated, ehich presented many problems with negative impacts on the performance of the line. In this way, the entire company’s performance suffers more costs than benefits, and that was the only way possible. Given the conditions and considering the imperative of Cartiere del Garda to drastically reduce the numbers of faults and improve accuracy, maintaining the performance of the system, the intervention was organized with particular attention and planned according to a detailed trial program made shares punctually timed and wedged into one another like a puzzle.

The stock enters the pits

Cartiere_del_Garda2

Before the beginning of the work, we start with the design and purchase of components. A team of LCS technicians on site positioned several laser sensors that, for installation in operation, would exactly reproduce teh entire map of the warehouse with the positioning of each individual coil. Later, before the starting date of the project, the operations were repeated with the staff working in the field.

Ten days. This was the time that LCS had available to replace worn parts, modernize the plant and the climate, change all engines, bringing the power from 500 to 400 volts, to mount a series of cameras, install the management and control software (WMS and WCS), replace old systems of communication cable with wireless devices and, above all, to rethink the system of laser detectors that enables the system to work even with a few inches of waste. And as if all this were not enough to make the project sufficiently “stimulating”, everithing was to be held in warehouse full, without moving anything inside stored.

Swiss organization, Italian heart

Cartiere_del_Garda3Notwithstanding some problems during the dismantling of the parts to be replaced and the inevitable unexpected that occur in this type of intervention, within 10 days the automated warehouse of Cartiere del Garda is back in a top form. Its performance is even improved. The new engines have optimized all movements bringing the number of cycles/hour from the previous 35 to over 45. The communication from the ground to the edge of the bridge crane, before cable was built in wifi and, thanks to a new monitoring system in real time, handling activities are under constant control. Last, but not least, the management in the category of electrical safety devices increased from wired to wireless (wifi) and at the same time increasing the level of PL (Performance Level – EN ISO 13849-1).

LCS not only renewed the system and restart it: when the revamping was completed, provided to Cartiere del Garda a detailed list of all spare parts in order to put the customer in a position to cope with the vast majority of failures and interventions of ordinary and extraordinary maintenance. In case of big problems to solve remotely, the task would be faced by the LCS service team. Cartiere del Garda has already had the opportunity to appreciate his efficiency and preparation. For this reason Cartiere del Garda assigned to LCS the revamping of the plant supervisor handling the cutting department.