Playmobil Optimizes Logistics with AutoStore

{{quote}}

The Horst Brandstätter Group's flagship brand, Playmobil, is a leading German toy manufacturer renowned for its expansive logistics network and large-scale European production facilities. The company operates major distribution hubs, including a centralized warehouse in Herrieden, Germany, which has implemented an AutoStore solution, empowered by Kardex.

With operations spanning more than 80 international markets, Playmobil requires efficiency and sustainability in their supply chain.They needed a solution that met their high-density storage needs while supporting their 2027 climate neutrality goal.  

‍

The Challenge: How to Expand Inventory in a Fixed Space

Playmobil confronted increasing demands on its spare parts logistics operations as its product line expanded and global reach grew. The company needed to efficiently manage both individual parts and complete playsets but was constrained by the limited footprint of its existing warehouse.

The company needed a solution that could maximize storage capacity within their current facility while providing the flexibility needed to handle the unique requirements of spare parts management. These small components demanded precision picking and accurate inventory tracking. Any new system also needed to align with Playmobil's goal of achieving climate neutrality by 2027. They needed a warehouse automation system that would reduce energy consumption while increasing operational and space efficiency.  

‍

The Solution: High-Density Storage With Automated Precision

The AutoStore solution at the Herrieden logistics center stacks Bins in a three-dimensional aluminum Grid, maximizing horizontal and vertical space.

Key elements include:

• ‍Grid and Bins: 16,376 Bins are stacked in the Grid, delivering four times the storage capacity of traditional warehousing in the same footprint.
• ‍Robots: 24 battery-powered Robots move along the grid, retrieving and delivering Bins as needed to workstations (CarouselPorts). ‍
• Workstations: Four CarouselPorts provide ergonomic workstations for efficient order handling.

Designed to integrate with existing warehouse infrastructure, the system now manages over 20,700 annual shipments globally and provides the scalability needed to support Playmobil's continued growth.

Key Benefits: Automated Efficiency and High-Density Storage

The AutoStore system delivered significant benefits to Playmobil's logistics operation:

• ‍4x increased capacity: The solution quadrupled storage capacity within the existing footprint. ‍
• Enhanced picking efficiency: Robots and workstations facilitate quick and ergonomic order processing, making spare parts easily accessible. ‍
• Sustainability: Energy-efficient Robots return energy during operations for later recharging and eliminate the need for aisle lighting, with 10 Robots consuming as little power as a standard vacuum cleaner. ‍
• Reliability: With a 99.7% uptime, AutoStore ensures uninterrupted 24/7 order fulfillment, meeting the expectations of Playmobil's global customers. ‍
• Growth-ready infrastructure: The modular design allows expansions without disrupting ongoing operations.

‍

Advancing Sustainability Through Warehouse Modernization

Beyond operational efficiency, AutoStore delivers substantial environmental benefits through multiple design innovations. The compact, aisle-free layout dramatically reduces the warehouse footprint while maximizing vertical space use. Robot energy consumption is minimal, and Robots return energy to their batteries during deceleration and Bin-lowering operations. Lighting requirements are also significantly reduced. These are the sustainability features that have earned AutoStore recognition with two Green Supply Chain Awards from Supply & Demand Chain Executive.

Project Specifications

• ‍Implementation type: Brownfield ‍
• Robots: 24 R5 Robots ‍
• Workstations (Ports): 4 CarouselPorts ‍
• Bins: 16,376 Bins ‍
• Warehouse Management System: Integrated with Kardex Mlog systems ‍
• Integrated technology: PutWalls ‍
• Integration partner: Kardex