GMP define internal logistics


Motivated by the system’s precision and speed, but especially by the good manufacturing practices, Altana Pharma build a warehouse with two stacker-cranes to service their new plant.

The concern regarding the GMP (Good Manufacturing Practices) was one of the main reasons that made Altana Pharma (new corporate name of Byk Química e Farmacêutica, since July 1st) opt for the installation of two stacker-cranes in their new plant’s warehouse. The plant opened about four months ago in Jaguariúna, in the Campinas region. The storage area, that is entirely computer-controlled, has a capacity of 5,818 pallets, consists of five aisles and occupies approximately 1,500 square meters. This area works like a “buffer” to store raw materials and packaging materials to supply the plant, imported semi-finished products, and finished products in transit to the logistical operator’s distribution center.

“The GMP were one of the main reasons that made us opt for the stacker-cranes “, explains the warehouse and expedition manager, Luiz Carlos Fogolin. “We also wanted to assure the operators’ safety and a precise storage and sorting of materials. Another benefit that influenced our decision was the fact that we are able to store in a logical and compact manner, occupying a relatively small area”.

The warehouse has two receiving and two expedition docks, and there is the possibility of opening another dock in each sector. Upon arrival, materials are sorted in a pre-storage area, where they are labeled, and then taken to the warehouse.

The storage structure is conventional; 22.5 meters headroom, and it’s closed with automatic, fireproof doors. The project foresees expansions to comply with future production increases. Inside we encounter a positive pressure environment, constantly eliminating air, which prevents suspended dust from coming in. There are an entry and an exit door for palletized loads that are interconnected by roller conveyors to the stacker-cranes. Another door gives passage to personnel and pallet holders. On the opposite side, in an antechamber with sealing doors, loads can be manually transferred from the wooden pallets used for storage to metal ones, which are the only ones accepted in the production area (the reverse is done at the product’s exit). A fourth passage, at a higher level located between the pallet positions allows the stacker-crane to forward raw materials directly to the weighing sector.

To avoid accidents that might be caused by moving equipment, the entire stacker-crane operation area is isolated by a grid, and also has safety mechanisms that interrupt the system’s operation when the entry door opens. One of the stacker-cranes covers two aisles and the other one, the remaining three. Two transfer cars, in the back of the warehouse, bring the stacker-cranes from one aisle to another.

Only six people work at the warehouse, and there is only one shift. “We could have chosen semi-automatic stacker-cranes with operators on-board, but our industrial director, H. J. Kilian, came to the conclusion that we wouldn’t have achieved the same dynamics as we have today”, notes Fogolin. “As it executes its tasks, the automatic system loads a data bank with information about the disposition of products in stock and distributes the pallets in the most rational manner (for ex. placing the items with higher turnover closer to the points of exit), and defines routes to accelerate traffic. It creates a traffic history and controls the exit optimization”.

 
Only six people work at the warehouse, and there is only one shift. “We could have chosen semi-automatic stacker-cranes with operators on-board, but our industrial director, H. J. Kilian, came to the conclusion that we wouldn’t have achieved the same dynamics as we have today”, notes Fogolin. “As it executes its tasks, the automatic system loads a data bank with information about the disposition of products in stock and distributes the pallets in the most rational manner (for ex. placing the items with higher turnover closer to the points of exit), and defines routes to accelerate traffic. It creates a traffic history and controls the exit optimization”.

The stacker-cranes are controlled by the Lakos system, and an interface is responsible for its integration to the SAP/R3 system (used by Altana Pharma). Raw materials are stored according to the FEFO-method (First to Expire, First Out”). Each stacker-crane moves about 50 pallets/hour. The pallets comply with the PBR standard and measure up to 1.30 meters, including the pallet itself. A software defines the maximum weight to be transported at a time, which normally is about 1 ton. A safety mechanism consisting of a calibrated spring and sensors prevents the equipment from functioning with loads that exceed the foreseen limit.

The stability is one of the equipment’s strengths. “The stacker-cranes and the shuttle cars do not jolt when starting or stopping the engine nor do they vibrate when moving”, mentions the manager. “At first, we thought of using a stretch film wrapper in the warehouse to stabilize the palletized loads, but we noticed that with the stacker-crane this tool and expense was unnecessary”.

The warehouse is equipped with fire safety systems, such as smoke detectors and sprinklers. The stacker-cranes and conveyors were supplied by Stöcklin Logistics Ltd., which in Brazil is represented by Vast-Besth. The storage structures are pallet holders supplied by Águia. The flooring (Serpal) was build following Stöcklin’s specifications for the project, according to the dimensions of the loads to be stored.    

Magazine:  Log&Mam  - July 2002

 

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Revista : Log&Mam - julho 2002