ABB DS boosts final assembly efficiency by 30–40% with Agilon warehouse automation

ABB's storage needs and the Agilon solution

The ABB Distribution Solutions unit (ABB DS) in Vaasa manufactures automation protection relays to safeguard medium-voltage networks and their devices. These products make power grids smarter, more automated, and safer.

"Our products are an important part of the switchgear systems in both ABB's factories and those of other equipment manufacturers," explains Production Manager Petri Kleimola.

Kleimola and Production Supervisor Sami Vesavuori are responsible for developing the production unit. One of their critical projects involved implementing and customizing the Konecranes Agilon automated warehouse to suit their needs. This development work has significantly improved production efficiency, functionality, and occupational safety.

ABB DS needed an efficient, space-saving automated storage solution, as storage space was limited. Critical selection criteria included ease of use and fast support in case of issues, as downtime could halt production.

"We found Konecranes' Agilon solution, compared it with other options, and received positive feedback. The system was the best fit for our needs, so we decided to invest," Kleimola explains.

Achieving growth by scaling and expanding the system

ABB DS implemented the Agilon system in 2019. As production volumes and storage needs increased, the system was expanded and updated with new functionalities. The current system, measuring 28 meters long and 6.1 meters high, has four user access points.

Agilon stores parts required for production orders, including cables and additional parts. Components are stored in their original packaging, with 99% of production components fitting into the system; only a few oversized products are stored elsewhere.

As production expanded, Agilon's flexibility allowed ABB to remove space-consuming pallet storage and make the layout more efficient.

"We expanded Agilon to utilize space optimally, removing the pallet warehouse and transferring items to the expanded system. It allowed us to reallocate floor space for production needs, increasing space efficiency," Kleimola adds.

Optimizing picking efficiency with automation

To improve the picking process and speed up material collection, Konecranes suggested features such as pre-picking, parallel picking, and batch picking. As part of the development project, Agilon was integrated with the SAP enterprise resource planning system, enabling comprehensive management of the production warehouse.

• Parallel picking allows the robot to efficiently deliver boxes to adjacent access points based on the order.
• Batch picking allows multiple orders to be picked simultaneously, speeding up the overall process.

Anticipating the next picking orders significantly improved operational efficiency. A new job role was created, enabling team members to train and become experts.

Pickers work in shifts, selecting required production orders from SAP. Agilon retrieves the necessary components and provides light guidance to ensure accurate picking. Once the picking is complete, the picker instructs the Omron mobile robot to deliver the orders to the production line.

Previously, the final assembly team collected components from multiple warehouse locations. Now, materials arrive directly at their workstations, significantly accelerating the process.

Ergonomic light-controlled picking tables

When Vesavuori learned about Konecranes' new light-guided Agilon picking cart, he suggested customizing the shelves and adding an ergonomic picking table to improve production efficiency and worker comfort.

"We proposed a picking table instead of the cart, with eight picking boxes to hold two assemblies each," he recalls.

This idea was quickly incorporated into the Agilon product development project, resulting in new functionality that improved both production efficiency and employee safety.

Measuring and improving efficiency

According to Vesavuori, ABB regularly conducts time measurements to assess the improvements in picking processes. "The measurements help us focus on the right areas for development."

These improvements have significantly impacted production, with time studies showing that picking efficiency in the final assembly has improved by 30–40%. The following development targets will focus on the pre-assembly process.

Error-free deliveries and satisfied customers

Agilon's integration, automation, and robotics have minimized human errors in the picking process. Barcodes ensure reliability and accuracy, and robots deliver materials directly to the production line.

Sami Vesavuori emphasizes that Agilon dramatically reduces picking errors, guaranteeing that customers receive the right products. "Agilon ensures we virtually eliminate mistakes, leading to higher customer satisfaction," he says.

Streamlined inventory process

Agilon streamlined ABB DS's annual inventory process. Production no longer needs to stop for inventory counts, and balance monitoring is reliable.

"Before Agilon, the annual inventory could take up to two days. With Agilon, we've cut that time significantly, saving hours and improving overall accuracy," says Vesavuori.

The inventory process is now handled directly through Agilon's portal, further simplifying the task.

User-driven development and future expansions

Production employees at ABB DS are enthusiastic about adopting new functionalities and actively contributing ideas to improve Agilon's performance. "We've received many valuable suggestions from users, which we pass on to Konecranes," explain Kleimola and Vesavuori.

Initially, the system had one robot, but as production volumes increased, they added a second. A third robot in the future prevents bottlenecks as production expands. 

"Collaboration with Konecranes is easy. They understand our processes and needs, making development and implementation smooth and efficient," Vesavuori concludes.

Customer-driven solution

Teemu Oittinen, Director of Development for Agilon, values the feedback from ABB DS and other customers. "Customer-driven development is the key to the evolution of the Agilon warehouse management system."

New functionalities, such as the ABB-conceived picking table and the new Agilon conveyor, are now available to all Agilon customers, showcasing how customer feedback shapes the future of warehouse management.

Key Agilon outcomes at ABB DS:

• Scalable and adaptable warehouse automation
• Optimized space utilization and flexibility
• Boosted efficiency and reduced errors
• Enhanced safety and streamlined processes
• Strong collaboration and customer satisfaction