Smartlog implements a new comprehensive picking and consolidation solution for MEBRA
Logistics automation that integrates the renovation of stacker cranes with an Autostore, a robotic order preparation system, in a single operational flow.
Smartlog has developed a comprehensive logistics solution for MEBRA that combines several order preparation subsystems, adapted to the nature and turnover of each item. On the one hand, there is a picking system for heavy, slow-moving products; on the other, an AutoStore system for small, fast-moving items. Both flows converge at a single order consolidation station, allowing for simultaneous and coordinated preparation from both systems. This hybrid architecture improves operational efficiency and facilitates the management of complex orders with greater precision.
The AutoStore system consists of eight standard R5 robots, 10,362 1.3-meter-high bins, two carousel-type ports for picking, and a Transfer Cell port for inputs. It operates using robots that move over a structure of stacked cubes, automatically extracting and depositing bins.
Next to the AutoStore is the customer’s stacker crane subsystem, connected via a single consolidation gantry equipped with lights per order, allowing up to six orders to be prepared simultaneously. This configuration optimizes workflow and significantly reduces preparation times.
The project also includes the implementation of the new Galys management software, the retrofitting of the mechanical control of the stacker crane, and the modification of the transport circuit, which will transfer the boxes from the stacker cranes to a new picking station located behind the AutoStore carousel ports. This design allows completed orders to be automatically consolidated and returned to the stacker crane.
MEBRA, based in Braga (Portugal), specializes in the distribution of hardware products and construction materials. Its activity is aimed at both the hospitality and retail channels, and is characterized by demanding operations based on logistical efficiency, proximity to the customer, and a high capacity to respond to changing demands. The company manages an extensive catalog that includes large-volume and heavy products, requiring flexible and precise logistics solutions.
Among the main challenges identified are the need to consolidate both systems without duplicating tasks, maintain traceability throughout the process, and adapt the solution to the space conditions of the warehouse without compromising efficiency.
The retrofit of the current stacker cranes developed by Smartlog includes replacing the PLCs with new commercial components, renovating mechanical and electrical elements, and implementing open-source management software for the customer. This operation is carried out on a scheduled basis, avoiding significant system downtime.
The operational benefits obtained translate into a substantial improvement in preparation efficiency and greater responsiveness to variations in demand. At a strategic level, MEBRA strengthens its operational capacity without the need to expand physical space, maintaining the flexibility and scalability of the system.
The solution is ready for future expansion thanks to the additional frame in the Autostore and the modularity of the transport system. This allows the operation to be scaled without affecting the current structure, adapting to new volumes and logistical needs.
The ability to consolidate heavy products with light items on a single pallet will be key to improving our operations. The new software, the renovation of our stacker crane, and the transport system will offer us a flexibility that we did not have before.
This project demonstrates how Smartlog can adapt to any specific customer need by offering a complete solution, combining new technologies, mechanics, and software in a single operational proposal.