Error-free and reliable

„Prostore“ mit Autostore-Anbindung beim HLSK-Großhändler Pietsch in Ahaus

The company motto of the Pietsch Group, headquartered in Ahaus in the Münsterland region, is "Grow or Go," or WOW for short. To live up to this guiding principle, the wholesaler for sanitary, heating, environment, climate, and ventilation has opted for an Autostore warehouse and the warehouse management system "Prostore".

At the Ahaus location of the Pietsch Group, the central warehouse is situated with cross-connections to all other locations of the corporate group. (Image source: Kurt Pietsch GmbH & Co. KG)
At the Ahaus location of the Pietsch Group, the central warehouse is situated with cross-connections to all other locations of the corporate group. (Image source: Kurt Pietsch GmbH & Co. KG)

The WOW strategy means for the Pietsch Group to continuously invest in the diversity and timeliness of their product range. This includes comprehensive service for customers as well as the spatial and technological expansion of logistics. The range of the HLSK wholesaler includes more than 600,000 listed items, including around 72,500 items that are permanently available. Anyone who orders from Pietsch by 8:00 p.m. on the previous day will generally receive their goods the next day. For processes to function reliably, a sophisticated warehousing and transportation system is required.

Diverse Product Range

Pietsch maintains four regional warehouses: in Ahaus in Westphalia, in Mülheim an der Ruhr, in Ritterhude near Bremen, and in Ostrau in Saxony. The company group also has its own fleet, consisting of 165 vehicles, which deliver to customers via daily, night, and city distribution. "The strength of wholesale lies in providing the right goods in the right quantity at the right time in the right place and with the right information and costs," explains Frank Leupers, authorized officer and logistics division manager at Pietsch: "The warehouse function plays a significant role in this." According to Frank Leupers, this is not always easy to fulfill because the product range of the Pietsch Group is very extensive and heterogeneous: from aerators for faucets,

sinks, and bathtubs to pipes for underfloor heating systems to boilers, water heaters, or complete heat pump solutions. Everything is included, whether large, small, light, or heavy.

Investment in the Future

The central warehouse is located in Ahaus, with cross-links to all other company group locations. The branch has 40,000 pallet spaces, spread across manually operated narrow and wide aisle warehouses and block storage areas. For small parts, an Autostore system with 61,500 containers was put into operation in 2024. Pietsch invested around 20 million euros for the expansion and modernization of the warehouse in Ahaus from the former 35,000 to the current 45,000 square meters. About five million euros of this were allocated to the Autostore system, plus preparatory activities for floor treatment, electrical connection, and fire protection. This makes the storage and picking of even more products possible.

Autostore was implemented within five months during ongoing operations. The system is directly connected to "Prostore" without middleware. It has since replaced an older small parts warehouse, which essentially consisted of a shelving system and a tray lift system connected via a conveyor system.

Picking was manual with the help of picking carts and a pick-by-voice technology. The shelving required comparatively a lot of space. "Space that we can use much more efficiently with the new, compact Cube system," describes Frank Leupers.

65 percent of items in AutostoreIn Ahaus, there are 61,500 containers on an area of 1,700 square meters. Each vertical shaft has 16 boxes stacked on top of one another, creating a total cube height of 5.30 meters. Each container can be used exclusively for one type of item or divided if necessary. This way, more stock items fit into the overall structure than there are boxes. "We now store 65 percent of our items in the 'Autostore' and only 35 percent in the remaining warehouse space," says Leupers. Additionally, 23 "Autostore" robots handle the storage and retrieval. In the receiving area, there are eight workstations each equipped with two "Conveyor Ports," while the shipping area has four "Carousel Ports" connected. This allows the system to achieve a throughput of 560 containers per hour in the shipping area. The pickers are noticeably relieved: instead of trekking through a shelving system every day, they stay at their stations and accurately pick the gray "bins" delivered from the Autostore. The items are packed either in black reusable containers or shipping cartons. A conveyor system with an integrated carton erecter, carton sealer, scale, and labeler completes the efficient order processing. "Connecting the new Autostore system is another milestone for us in the comprehensive digitization of our logistics," emphasizes Leupers.

"Prostore" for optimal material flow

The fundamental requirement for all processes is a powerful software environment: Pietsch uses SAP as the overarching ERP, and the Warehouse Management operates with "Prostore". The collaboration between Pietsch and Team has existed for a long time — since 2009, Team has been accompanying the wholesale company in controlling and optimizing the material flow. Various expansions and modernizations have been carried out, and the Warehouse Management has been continuously adapted to new requirements.

The challenge was the high level of dynamics. The commissioning took place within just four weeks. "During this time, we had to dismantle the old small parts area and transfer the goods to the new Autostore with its adjoining periphery," recalls project manager Detlef Rebbert of Team GmbH. "There were many distribution and connection processes. These were not allowed to disrupt the ongoing operations. Additionally, it was necessary to continue keeping an eye on route optimization."

Better availability and faster delivery

Logistics manager Leupers from Pietsch is pleased with the optimized processes: "Our logistics chain from goods receipt through order picking to delivery is practically error-free and has a reliability rate of 99.7 percent." The service quality of logistics has also significantly increased due to the digital innovations. "Our customers benefit from even better product availability and even faster deliveries. By further increasing our efficiency, we are also saving costs that we pass on to our customers in the form of competitive prices."

Translated automatically from German.
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