ProStoreSUCCESS® STORY ProStoreSUCCESS® STORY at FRoSTA at FRoSTA

Hightech on ice  In 1998, the FRoSTA AG, specialist for high quality frozen products, laid the foundation for a clear commitment to as a manufacturing base at its head- quarters in . The com- pany started the project „Schottke 2000“ and invested heavily in an ad- vanced production line, a new ware- house for raw materials and a forklift control system for the optimization of the logistic processes. Even then, further extensions plans that were to reach well into the next decade had been made and FRoSTA was resolute in realizing them. Since 2001, TEAM‘s logistics software Pro- Store® pulls the strings of the FRoSTA logistics. All extensions and modernizations were made with a new interface to Pro- Store® and realized during ongoing FRoSTA in Bremerhaven: High quality frozen products manufactured according to the FRoSTA purity law operation.

ProStore® components ƒ Radio-based forklift control Please contact us. We are looking FRoSTA AG is the market leader in The required pallets are transported Every store movement is triggered system (Web SLS) forward to hearing from you. ƒ Goods receipt frozen ready meals in Germany with fully automated on roller conveyors and registered by TEAM‘s logistics soft- ƒ Harvest processing (Rheintal TEAM GmbH roots dating back to 1905. Since and chain roads to the production via ware ProStore®. For this purpose, the ƒ Storage plant) 1978, the company consistently re- a 70 meter long bridge. program is connected to the SAP ERP- Hermann-Löns-Straße 88 ƒ Quality assurance lies on building the FRoSTA as system, which was introduced in 2005. ƒ Yard management (truck sum- 33104 Paderborn There, they are finely distributed by a guarantor of high quality frozen ƒ Re-positioning of stocks monsing system in Bremerhaven) the ProStore® forklift control system. The ERP System controls all goods re- Fon +49 5254 8008-0 products. In 2003, the company in- Transport orders for the finished goods lated operations, beginning with the ƒ Warehouse management ƒ Visualization component for Fax +49 5254 8008-19 troduced a purity law for its products are also generated in the production purchase of goods. It notifies expected „Dinner International“ (fully auto- and thus forgoes the use of color- ƒ Material flow control Mail [email protected] area and the pallets are then stored incoming goods, including the deli- mated production line) and yard ants, additives and flavour enhancers Web www.team-pb.de in the fully automated shipping ware- very plans, to ProStore® by creating ƒ Production supply and disposal management which is unique in the conventional house. corresponding orders. When goods via mobile terminals ƒ Connection of external service food industry. In 2009 the company are delivered, the staff opens the ƒ providers via data interface More success stories achieved a turnover of around 400 During the entire flow of materials, the Shipping ProStore®-screen, acknowledges the www.team-pb.de/references million . ProStore® forklift control system con- ƒ Stocktaking ƒ Connection of scales (Mettler- receipt of goods and automatically trols all transport commands and thus Toledo) in the spice weighing Automatic goods movements for compares the data to the plan. ƒ Inventory management provides an optimal material supply ƒ Sending and receiving of dispatch optimized processes ƒ Master data management for and from the production. advice message (EDI DESADV) The two fully automated production ProStore® registers each movement ƒ Information system lines in Bremerhaven can process up Hardware and tools of goods in the warehouse ƒ to three parallel jobs and produce up Batch tracing ƒ LINUX server to 6,000 kg of finished dishes per line It’s minus 26 degrees in the warehouse ƒ Host connection (SAP) ƒ Oracle database and hour. The warehouse for raw ma- for raw materials (FWD III) and it is so ƒ Connection of automatic stock ƒ Oracle application server terials (FWD III) provides the producti- cold in production area that the cold control including emergency on with frozen ingredients. It can hold chain is guaranteed not interrupted

ƒ STORY SUCCESS SUCCESS STORY SUCCESS strategies Approx. 600 users at 4 location more than 12,000 pallets. during the short production times.

ProStoreSUCCESS® STORY at FRoSTA

“Dinner International”: The products are constantly checked During the entire production process In the formulation of the functional specification the experience of the staff was considered fully automated production line for quality the cold chain is not interrupted

If the supplier has previously announ- The ERP system then transmits the After the handover at the target loca- lets are generated, the pallets are re- In collaboration with TEAM very early and a yard management (truck sum- ced the delivery of pallets via electro- data to ProStore®. Here they are pro- tion, the driver acknowledges the pro- leased fully automated from the high training sessions were conducted. This monsing system) has been included. nic data interchange, scanners at the cessed and then returned online to cess. Hereby the consumption of the rack warehouse and are transported good preparation has paid off. From External service providers were con- conveyor system receive the goods au- SAP. Thus, both systems (SAP and Pro- raw materials palette is reported to to the corresponding shipping gate. the very beginning all employees were nected to the system via interfaces, tomatically. Parallel to the booking, a Store®) work with identical data bases. SAP. It only takes a maximum of eight After the goods have been loaded, able to operate ProStore® easily. and thus a much higher degree of GS1-128 label is printed that identifies minutes from the raw materials requ- ProStore® automatically generates the process automation has been achie- the pallet. Quality assurance takes a Reliable supply of raw materials est to the delivery at the production delivery note, reports the loaded goo- Continuous enhancement ved. of the systems first sample from the pallet and puts a A ProStore® terminal, which displays line. ds to SAP and the inventory is updated. sample board of each pallet together. When indicated, ProStore® sends an A positive outcome the production order to the line ma- ProStore® forklift control system The introduction of ProStore ® achie- The sample board is labelled with an nager is installed at each production additional dispatch advice message ved significant cost savings from the The Logistics department, which was SSC (Serial Shipping Code), hereby it line. The line manager logs on with the FRoSTA uses a very advanced wireless (DESADV) of the pallets to the custo- early years. But not enough, step responsible for the new building of may be assigned to the pallet at any production order number and receives forklift control system. Thirty RF - ter mers or the carriers respectively. by step the intralogistic processes the high rack warehouse for raw ma- time. Now a transfer car brings the a job-related bill of materials with all minals are installed at the production were modernized and optimized con- terials as well as for the introduction Early information and involvement goods into the warehouse. the details on the articles and quanti- lines and another twenty terminals are sistently. of ProStore® in all FRoSTA plants, are of the employees guarantees success ties needed for production. If he, for installed on the forklifts in the produc- very pleased with the results. “The The goods now have the status „not ProStore® was introduced in the example, clicks on the item “peas”, he tion and the storage areas. Radio aeri- new building of the high rack ware- yet freely available.“ Only the quality Almost exactly one year passed from FRoSTA plants in Elbtal, Rheintal and automatically initiates the stock remo- als which ensure a seamless communi- house for raw materials and the in- assurance can revoke this restriction the formulation of the specification to () and a number of val of this article. cation are distributed throughout the troduction of ProStore® in all opera- by giving it the all clear. the initial operation of ProStore® in Ja- new modules and functions were put premises. tive areas of FRoSTA have significantly Every stock transaction determines a nuary 2001. For the people in charge into operation. Automatic storage into high rack improved logistics. change of inventory in the system. The The production demands are transmit- of this project at FRoSTA, it was of cru- warehouse These include the integration of spice pallet with the peas is transported via ted by radio to ProStore®, which gene- cial importance for the success of this All operative processes are run pa- weighing with automatic integration The storage is done dynamically, whe- the conveyor bridge to the production rates a transport order with optimized complex task to arouse the interest perless and fully automated. We of scales, the expansion of the produc- rein a plurality of optimization criteria area. Just before the conveyor deposits transport routes. of all participating colleagues, and to were able to reduce costs and we can tion lines for the international ready is taken into account. The software the pallet in the supply area, a fork lift create understanding for the extensive point to a much improved stock avai- Optimized picking processes meals (“Dinner International”) and the also considers security aspects. Each driver gets the order to pick up the pal- innovations and changes. lability.” The order picking in the shipping ware- introduction of a modern visualization article is placed into more than one of let. This order is generated automati- For this purpose, early internal infor- component. STORY SUCCESS the four rack corridors. This guaran- cally and displayed on the RF terminal house is paperless. A tour-oriented dispatch is then organized. Some of the mation events were organized, from tees a permanent access to all articles, installed in every fork lift. The fork lift In addition, the harvest processing in carriers can carry out the route plan- which the project managers also even in case of a control device failure. driver takes the pallet, scans the Serial the Rheintal plant has been optimized, ning directly in ProStore®. The appro- received a lot of inspiration from other The SAP system creates records for all Shipping Code (SSC) and immediately the control of the high rack warehouse val of a tour initiates the dispatch. departments and divisions that could production and shipping orders as well the RF terminal displays to where he be included in the description of the including various emergency strategies as for all orders of goods. has to bring the pallet. Transport orders for the required pal- tasks. in Bremerhaven has been integrated