The Challenge
The procurement of medical supplies, such as surgical instruments, gauze, plasters, and emergency products has become increasingly important. After the Covid-19 pandemic, the need for readily available disinfectants became widely recognized. IVF HARTMANN, based in Neuhausen, Switzerland, is a subsidiary of Germany’s Paul Hartmann, a leading medical and healthcare manufacturer. Since 1871, the company has produced and supplied surgical instruments, plasters, diagnostic equipment, hygiene and disinfection products, and other healthcare materials, mainly to hospitals and pharmacies.
For many years, storage and order processing were handled manually. However, rising demand in recent years created a need for faster processing, leaving warehouse and delivery staff increasingly overwhelmed.
To expand capacities and to respond to customers more quickly, the management team resolved to automate its intralogistics processes at its Neuhausen am Rheinfall site.
"The greatest obstacle we faced in our dilemma was coming up with a high-performance solution for a very limited space," notes Thomas Mayer, the head of Logistics at IVF HARTMANN. Due to its direct proximity to Europe's most powerful waterfall, the Rhine Falls, expanding the site was not an option for the healthcare specialist.
The Solution
IVF HARTMANN partnered with Armstrong Dematic, whose German office in Heusenstamm provided an innovative 2-story Multishuttle system. Instead of a large single-level setup, Armstrong Dematic designed a compact two-floor solution covering just 400 sq. meters. The ground floor houses order picking, while the upper floor contains the Multishuttle warehouse, connected by lifts and only 290 meters of conveyor.
The upper level now features a 3-aisle Multishuttle tray warehouse with about 10,000 bin locations across 20 levels. Sixty shuttles replace the former manual handling, and totes move automatically between levels via high-speed lifters operating on parallel buffer tracks.
"With the storage and order-picking areas directly above each other, we can save time with shorter internal transport routes and by optimizing our logistics processes. We are also now able to make the best possible use of the space available, which is a real benefit," notes Mayer.
Effective and ergonomic order picking
On the ground floor, items are sent to one of three picking stations, where a put-to-light system shows employees exactly where to place each item, minimizing errors. Each station can handle up to eight orders at once, and the Multishuttle delivers trays in sequence for efficient picking. Workstations are also ergonomically designed, with empty totes positioned at a comfortable height.
Once an order tote is full or complete, it is automatically sent to packing. Packed goods move on for dispatch, while empty totes return via a dedicated conveyor. The entire process—from picking to packing—is streamlined with technologies like put-to-light and ProGlove scanners.
Simplifying the software landscape
Alongside automating the Swiss facility, Armstrong Dematic also digitalized IVF HARTMANN’s warehouse operations. They replaced the old SAP system with SAP EWM and integrated their own SAP Material Flow System to optimize resources and map every process from goods receipt to goods issue. HARTMANN wanted a scalable design that could be used at other sites, and now real-time data feeds into EWM to ensure smooth, efficient warehouse workflows.
Thanks to the implementation of proven standards, the control level (PLC) is directly connected with the SAP EWM. Project-specific implementations were eliminated, which lead to shorter implementation times and low-fault operation.
Mayer sums up: "The cooperation with Armstrong Dematic was one built on trust from the very start. The solutions they came up with and their process support completely met our expectations. Thanks to our new logistics centre, we are now in a much better position to meet our customers' requirements."
The Results
In a space covering just 400 sq. metres (roughly 4,300 sq. feet), the global automation technology supplier implemented a highly efficient space-saving solution which involved a 3-aisle high-speed Multishuttle system and an order-picking area with a put-to-light system underneath. Armstrong Dematic also installed a manual high-bay and order-picking warehouse in the new building. For facility management, IVF HARTMANN relies on SAP Extended Warehouse Management (SAP EWM) software package with Armstrong Dematic SAP Material Flow System.
Technical Data:
- An integrated space-saving concept for 400 sq. metres (4,300 sq. feet)
- Armstrong Dematic Multishuttle tray warehouse with three aisles, 20 levels, 10,000 storage locations and 60 static shuttles
- Three ergonomic put-to-light order-picking stations directly below the multishuttle warehouse where up to eight orders can be simultaneously processed
- Just 290 metres (950 feet) of conveyor technology
- SAP EWM system with a Armstrong Dematic SAP Material Flow System.
Customer Benefits:
- Robust solution in a limited space
- Faster order processing speed and quicker delivery to customers
- Greater accuracy and enhanced ergonomics in order picking
- Latest software package of SAP Extended Warehouse Management (SAP EWM) with the Armstrong Dematic SAP Material Flow System serves as a template for the rollout to future locations
About IVF HARTMANN
IVF HARTMANN AG has been a leading Swiss manufacturer of medical supplies for over 150 years. The healthcare specialist, based in Neuhausen am Rheinfall, has been a member of the international HARTMANN GROUP since 1993. Its business segments include wound care items, incontinence, risk prevention in hospitals and assorted first aid supplies. In addition, other product segments such as cotton wool or heat plasters are sold. IVF HARTMANN employs nearly 330 individuals in Switzerland.
