At Pöppelmann GmbH & Co. KG, mobile robots from Safelog are now taking over the entire container transport in the K-TECH division. The system replaces a manually operated shuttle train and is intended to lead to a noticeable relief for the employees as well as to greater efficiency in production supply.
“The shuttle trains were very loud, a real noise nuisance in the halls,” describes Michael Czwaluk, Logistics Team Leader at Pöppelmann, the previous situation.
Additionally, loading and unloading the trailers had been a physical challenge for the staff that was no longer compatible with ergonomic considerations.
“Besides increasing efficiency, it was important to us to find a solution that reduces the physical burden on employees,” Czwaluk continues.
The transition was carried out while operations were running and is part of the company's comprehensive digitalization strategy.
The
Lohne-based company employs around 2,500 employees and operates about 700 injection molding machines at six locations. In the K-TECH division, plastic parts are manufactured for the automotive and industrial sectors. A production hall with 30 machines has now been reorganized logistically.
Container transport by shuttle train
The challenge was to reliably deliver empty containers to the machines and to efficiently transport loaded load carriers back to the warehouse. Previously, a shuttle train with three trailers handled the transport of the floor rollers. The wagons had to be loaded and unloaded manually, which was physically demanding and time-consuming. In addition, there were noise problems and a lack of flexibility in the system. The material flow could not respond to fluctuations in output, which led to waiting times.
Mobile robot “M4 lift” from Safelog: flat design and 1,000 kg
payload
After a market analysis, Pöppelmann chose Safelog as automation partner. Christoph Dierken, Head of Logistics, Plant 2, and Michael Czwaluk prepared, at first, a list of 20 service providers that could be considered. After initial discussions, four candidates remained, with whom they entered into negotiations. In the end Safelog from Markt Schwaben convinced them with their technology and the price‑performance ratio.
The mobile robot “M4 lift” from Safelog features a flat design, a high payload of up to 1,000 kg and great maneuverability – crucial in tight spaces. Eight of these robots currently handle the material flow at Pöppelmann. A ninth vehicle serves as a reserve and is used only in production‑heavy phases.
The cycle begins at the “station” in the warehouse. There the robots pick up empty floor rollers, drive them to the machines and
pick up fully loaded load carriers again. Empty trips are avoided through a well‑designed driving strategy.
Contour-based navigation using a digital hall map
Navigation is contour-based using a digital hall map. The robots orient themselves, for example, by reference to columns, injection molding machines or hall doors. Additional guiding lines or magnetic tracks could be dispensed with. Safety sensors ensure interaction in mixed operation with forklifts and plant traffic.
The fleet is controlled agent‑based – each robot has its own computing unit. If a device fails, the other vehicles take over the tasks, ensuring high fault tolerance.
The implementation was carried out gradually. With the help of a commissioning software, the vehicles were brought into operation one after another. For the people responsible, the introduction went smoothly. Other projects, such as automation of downstream logistics processes, are
