FILM LOGISTICS: Optimisation strategies – #4 Automation

At last, greater productivity in the film warehouse! In our series so far, we’ve shared tips on process organisation. Now we’re looking at automation – and how you and your staff can benefit from it. By NEPATA CEO Fabian Franke. Of course, automation can boost productivity. Used correctly, it can also significantly reduce errors and thus prevent waste. We have developed our own products and solutions in the field of automation. Having been in this business for over ten years, Nepata stands out because our solutions allow orders to be processed directly from the ERP system or online shop. With software support, you can avoid sending rolls that are too long or too short, incorrect colours, matt instead of gloss, etc., or the classic scenario: six metres are cut from a ten-metre roll for the customer, but the customer is sent the four-metre remainder because an employee made a mistake.

We can avoid such errors by using software support – in other words, a conversion centre, a rewinding machine or a slitting machine in conjunction with the ConvertPlus software. The data entry process is automated, so there is no risk of typing errors or omissions. Crucially, barcode scans are used to cross-check the material against the actual order, ensuring that no mix-ups can occur. All of this takes the pressure off logistics staff, particularly when things get busy. From a business perspective, it can be said that the speed of the process also boosts overall productivity. We have received feedback from our customers: one can expect productivity gains of between 40 and 50 per cent compared with a manual wrapping system using simple machines or devices. Added to this are the savings resulting from greater accuracy and the avoidance of waste.

Another point I would like to mention here is our automated storage systems. Even tasks that do not directly add value – namely, fetching and returning vinyl rolls to and from the machine – can now be fully automated. The rolls are placed in a storage system with a gantry robotor – for smaller warehouses – in a storage system with an industrial robot. The robot pre-sorts the rolls onto trolleys according to which ones are needed next, as specified by the order queue in the software. Staff can concentrate on carrying out the orders at the machine. They place the remaining rolls back onto the trolleys, return these to the system – and the goods are then automatically put back into storage. At all times, the robot has a complete overview of everything in stock, which roll needs to be processed next to avoid it being overtaken by other stock, or which roll is particularly well-suited to the current order in terms of length. These are all tasks that employees naturally find difficult, particularly when under time pressure, and where there is significant potential for optimisation.

Here you can read our recommendations on transport routes, machine utilisation and the handling of cardboard tubes. Alternatively, you can make use of our advice on Film Logistics and digitalisation. We take a highly personalised approach to your business – even if you do not (yet) use NEPATA machines.

https://www.youtube.com/watch?v=haY0OTJrPsw