Case study Cosentino

Case Studies Case Study Cosentino

The Company

Cosentino Group is a Spanish company, family-owned but globally oriented, which produces and distributes innovative and sustainable surfaces for the world of design and architecture.

Cosentino works with its customers and partners to offer design solutions that add value and inspire people’s lives. This goal is made possible thanks to leading brands such as Silestone®, Dekton® and Sensa by Cosentino®. Technologically advanced and environmentally friendly surfaces that allow the creation of unique designs for the home and public spaces.

CUSTOMER NEEDS

COSENTINO needed a global solution to fully automate the logistics of the Silestone® and DEKTON® systems, which included collection and transport of slabs from production lines, integrated management of the distribution center via SAP, planning and preparation of loads.

Special elements have therefore been developed for handling the final load unit (vertical slab), including high tonnage AGV vehicles and a fully automatic loading system, in order to guarantee delivery times, quality in the preparation of orders and care in loads preparation. Furthermore, the technological challenge of sending the slabs to the customers in the same conditions as before the automation was met, thus without involving modifications or need for machinery for the customer. Cassioli was selected as supplier by Cosentino, with the task of developing an innovative solution that included the entry system to the distribution center, stacker cranes with a high load capacity, modules for order preparation and integration with Cosentino ERP / SAP. The distribution center project was designed from the outset as a modular installation: there were built 2 blocks with 3 stacker cranes each and 4 automatic preparation points for slabs.

COSENTINO requested to treat each slab in a univocal way, in order to have a total traceability of each of them and of the information contained within them (barcode), i.e. production, storage and shipping parameters. The focus was placed on the optimal quality of each table and loads and finally on ensuring flexibility, speed and robustness to the system (work 24/7).

Cassioli has developed and built a
storage system with 9 stacker cranes
working in 3 blocks of the warehouse;
each block is independent in terms of
accessibility and maintenance.

The automatic warehouse covers a total of 4,500 square meters and is 32 meters high. Warehouse entrances and exits can be carried out on two levels, while the preparation of orders takes place at level 0, through automatic systems specially designed for Cosentino processes.

The packages arrive from the production lines through automatic conveyors and SLS shuttles, then they are directed to a shape and data control system (automatic reading of all the bar codes), which verifies their suitability. If the system detects that the package is correct in all its parameters, it continues the path, otherwise it is rejected and submitted to the control of the Cassioli software. Once the parcel reaches the front of the warehouse, it is directed to a specific warehouse through SLS system (Shuttle Loop System) to the entry position, where it is picked up by the stacker crane designated by the Cassioli WMS software.

When a package is required for the preparation of a specific order, it is picked up by the stacker crane in the warehouse and then placed in the special order preparation area by means of shuttles, to give greater flexibility and ensure that all packages can be addressed to any preparation area.
The system takes the slabs one by one following the specific sequence requested in the loading order (perfectly integrated with Cosentino SAP); in the event that there are slabs in excess, the load returns to the warehouse and the slabs are grouped in a new load, always automatically.

Once ready, the load is taken to an automatic strapping station and then made available to the LGV (Laser Guided Vehicles) to be placed in a temporary buffer or to be loaded directly onto the truck, through the automatic loading system.

Automatic warehouse with a capacity of 11,500 packages up to 3,500 kg, with 9 special stacker cranes with forks that pick up the pack of slabs from the long side
Handling systems with chain conveyors, roller conveyors and tilters for special slabs
Elevators for packages and slabs
Manipulators for slabs preparation (handling of one slab at a time)
Traceability system for data and dimensions
Integration with automatic systems of: strapping, high tonnage AGV and manual operations
Cassioli WMS

Advantages

Fully digitalized industry

100% INCREASE IN STORAGE CAPACITY

Maximum exploitation of the available space
(HEIGHT STORAGE UP TO 32 M)

Significant reduction of the work force and risk of operational accidents practically eliminated

Increase
in production
efficiency

Maximum
organization
of the working environment

“INDUSTRY 4.0”
ECONOMIC BENEFIT

Automated Warehouse

DISTRIBUTION CENTRES AND PICKING SYSTEMS

AUTOMATED VEHICLES

CONVEYORS

AUTOMATIC WAREHOUSES FOR TIRES, GREEN TIRES AND RAW MATERIALS

GANTRY ROBOT CARTESIAN MANIPULATOR

AUTOMATIC ROBOTS FOR TIRE PROCESSING AND PALLETIZING

EMS MONORAIL TRANSFER SYSTEM FOR GREEN-TIRE HANDLING

CONVEYORS FOR THE TIRE INDUSTRY

INTEGRATIONS / OTHER TIRE DIVISION PRODUCTS

FAST2CHECK ATRS Automatic Tray Return System

BHS – Baggage Handling System

ULD Stocking -
Parking area

Assembly lines

ROBOTIC WORKSTATIONS

CLS - Cart Loop System

Case study Cosentino

The Company

CUSTOMER NEEDS

The Cassioli solution

Advantages

DOWNLOAD BROCHURE

Case study Cosentino

The Company

CUSTOMER NEEDS

The Cassioli solution

Advantages

DOWNLOAD BROCHURE

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