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Case study Arcelik

The Company

The Arctic Ulmi factory, in Dambovita County, Romania, is the largest household appliances manufactoring plant in Eastern Europe.

Since 2002, the majority shareholding of Arctic has been acquired by the Arçelik group, which invested over 135 million euros in new technologies and in modern production management systems, making possible a substantial increase in the production capacity. The construction work on the Ulmi washing machine factory started in 2017. Built in just 17 months, on an area of over 700,000 sq m, this factory implements the latest technological innovations and automation processes of Industry 4.0, with intelligent equipment, interconnected devices and cooperative robotic technologies. The production capacity of 2.2 million washing machines per year makes it one of the largest and most efficient plants in the world.

CUSTOMER NEEDS

The customer turned to Cassioli for the automation of the warehouses and the connection of the plant production lines.

The Ulmi factory, specialized in the production of washing machines, needed state-of-the-art automatic systems, capable of storing raw materials and finished products, as well as automatic handling systems for the supply of assembly lines for washing machines.

The entire plant within the Arctic factory in Ulmi is spread over 3 different levels: the ground floor, the mezzanine floor at a height of 5 meters and the floor where the EMS shuttles operate, at a height of 9 meters.

Inside the plant there are 4 different automated warehouses and different handling systems that allow to move all types of material and products in a completely automatic way.

Cassioli allowed the automation of the entire assembly process, making sure that the factory was fully digitalized, thus obtaining a significant reduction in production times and operating costs. The systems installed allowed the storage of the 4 main elements that make up the washing machines, namely tubs, tub covers, baskets and cabinets.

All these components, once manufactured and verified in the test areas, are transported through special automatic conveyors and SLS shuttles to the warehouse. In addition to the storage of these 4 components, Cassioli has also created special lines and automatic systems for the handling and storage of other components, necessary for the assembly of washing machines.

To do this, conveyors, SLS trolleys, AGV and EMS automatic vehicles were used. The components from the suppliers are transported to the warehouse through conveyors and then, through EMS shuttles that move on suspended tracks (up to 84 dropping points), are positioned on the ground where the crates with the components are lowered from above, so the operators receive the materials to be assembled.

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The Cassioli solution

  • 4 Automated Warehouses
  • 18 Stacker Cranes (Miniload and Unitload)
  • 1200 meters of RGV lines
  • Chain conveyors
  • SLS, Rail Guided Vehicles
  • 16 dropping point for AGV
  • 66 EMS, Electrified Monorail Systems
  • 84 dropping point for EMS
  • Supply lines for the assembly of washing machines

Advantages

Fully digitalized industry

INCREASED PRODUCTION
EFFICIENCY

SIGNIFICANT REDUCTION
OF THE RISK OF ERROR

REDUCTION IN
OPERATING COSTS BY 11%

CASE STUDY

Automatic Storage
Retrieval System
ARCELIK

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