Spare parts logistics concept with short-term layout planning

An Agile Project Approach for Short-Term Layout Planning

Mainova AG is one of Germany’s largest regional energy providers and supplies approximately one million people with electricity, natural gas, heat, and drinking water. As part of the renovation of a coal-fired power plant in Frankfurt, the existing spare parts warehouse had to be dismantled on short notice. Building a replacement facility was out of the question due to the tight schedule. To continue ensuring the security of supply, two temporary rental warehouses were to be planned and equipped with the necessary warehousing technology. Rothbaum Consulting developed the logistics concept for this project, prepared the request for proposals, and provided support with the inventory analysis and product assortment planning.

The photo shows Dr. Mark Jacquemin, head of logistics at Mainova AG.

Thanks to Rothbaum’s expertise in warehouse planning and project management, we were able to stabilize the tight schedule and use the project results for rapid implementation.
Dr. Mark Jacquemin, Head of Logistics, Mainova AG

Rapid Implementation of a Future-Proof Spare Parts Logistics System

Challenge

The main challenge was to dismantle the existing spare parts warehouse on short notice, even though no replacement building was yet available. At the same time, it was necessary to ensure a high level of spare parts availability to guarantee supply security and to establish a suitable interim solution for storage.

Implementation

Working closely with the Mainova warehouse team, we created a planning database containing the relevant product range data. During joint workshops, we developed and refined numerous layouts. We then compared the options from both a technical and economic perspective, selected the preferred option, and put the technical equipment out to bid.

Results

Based on SAP inventory levels and material flows, the warehouse areas were sized and the appropriate warehouse types were determined. In parallel with the site search, layout planning for two warehouse locations was carried out, and a request for proposals for technical warehouse equipment was issued. Both warehouses were occupied in mid-2022, and the existing warehouse was handed over on schedule.

2

Deposits

100%

Availability as a Key Planning Assumption

Mid-2022

Move into the new warehouse and timely handover of the existing warehouse

Preparation of a functional tender document for the technical equipment of the warehouses, neutral comparison of the offers and advice in the award decisions

Detailed Results

SAP inventory levels and material flows were analyzed, and the master data for warehouse items was enhanced in collaboration with the Mainova warehouse team.
The various storage areas for long items, heavy loads, small parts, pallets, and mesh boxes were sized, and appropriate storage types were determined based on access frequency.
Two warehouses were planned with cantilever, pallet, shelving, and floor storage systems and designed in accordance with relevant planning criteria such as floor load, building height, elevator size, and fire safety.
Layout planning was carried out in parallel with the property search to enable the temporary solution to be implemented quickly.
The technical warehouse equipment was put out to bid on a vendor-neutral basis, and the bids received were compared on technical grounds.
Both warehouses were occupied in mid-2022, and the warehouse scheduled for demolition was handed over on time.

rothbaum-consulting-success-story-spare-parts-logistics-mainova

Philipp Kappus

Senior Production Manager

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