Mastering Complexity: Precision-Driven AutoStore Installation
In the fast-paced world of logistics, precision and efficiency are key. NPSG Australia has once again demonstrated its expertise with a complex AutoStore installation in Melbourne for a customer of Dematic, one of Australia’s leading logistics automation suppliers, seamlessly integrating advanced technology with meticulous engineering.
A Unified Approach: Mezzanine and AutoStore Installation
The installation was executed with a methodical approach, as the mezzanine structure and AutoStore system were constructed concurrently. This synergy allowed the AutoStore to extend atop the mezzanine, maximising space and operational efficiency. The final touch was the installation of the conveyor system, marking the completion of this project.
The Challenge of Second-Hand Materials: Precision Meets Experience
Working with second-hand materials always presents unique challenges, particularly when installing a system as precise as the AutoStore, where tolerances are measured in mere fractions of a millimetre. NPSG Australia thrives on a challenge. This project was a testament to the team's skill and adaptability, turning potential hurdles into opportunities for innovation and improvement.
The AutoStore system installed in this Melbourne warehouse is a marvel of modern logistics technology. Designed to optimise space, it houses 6,000+ storage containers, each managed with pinpoint accuracy. The system strategically stores items based on their demand frequency, ensuring that the most requested products are easily accessible, while less frequently needed items are stored efficiently.
This installation wasn’t just about placing equipment; it required careful planning and execution. The system transitions from the ground floor to a mezzanine, incorporating a maintenance platform for easy access. Below the mezzanine, four carousel workstations were installed, while two induct stations were positioned beneath the maintenance platform.
The installation process was meticulous, beginning with the grid layout on the ground, erecting uprights, assembling the top grid and track system for the robots, and finally, installing the façade. The site’s layout presented additional challenges, particularly in transitioning the system to the mezzanine and managing the second-hand materials. Damaged parts needed to be identified, verified, and either repaired or replaced, often requiring custom adjustments like making cut-outs to ensure a perfect fit.
Despite these challenges, the project was successfully handed over, with the system’s required precision fully achieved. The team’s adherence to process and the implementation of a new internal installation method significantly improved the speed and efficiency of the build.
Constructing the Mezzanine: A Task of Precision and Adaptability
Building the mezzanine was a project in itself. NPSG Australia was tasked with erecting two-thirds of a mezzanine that had been disassembled from another warehouse and transported to its new location. This involved a careful process of identifying and sorting the necessary components—columns, beams, and purlins—from the rest of the disassembled structure.
Once the components were sorted, the team drilled holes for the columns, which had been precisely marked out by a surveyor prior to NPSG’s arrival on-site. Stability was ensured by securing the columns to the floor with Ramset chemicals and bolts. The columns and beams were then carefully erected using a forklift with a jib attachment and lifting straps.
Ensuring the structural integrity of the mezzanine was paramount. The team employed laser levels to confirm the columns were perfectly vertical before adding the purlins and laying the floor. This stage presented the most significant challenges, as the MDF board floor had suffered damage during transport, and some sections had lost their identification numbers. However, through careful work and resourcefulness, the team completed the floor using spare parts from the unconstructed sections.
Conveyor Installation: Precision and Simplicity
The final stage of the project involved the installation of the conveyor system. Conveyors, though seemingly simple to install, demand absolute precision. Proper positioning and alignment are crucial for optimal performance, and NPSG Australia’s commitment to perfection ensured that the conveyors were installed flawlessly.
A Triumph of Teamwork and Expertise
The successful completion of this AutoStore installation is a testament to NPSG Australia’s ability to tackle complex projects with precision and efficiency. From the integration of second-hand materials to the installation of advanced automation systems, the project highlighted the team’s expertise and adaptability. With every challenge met and every goal achieved, NPSG Australia continues to set the standard for excellence in warehouse automation.
Photo: NPSG Australia staff onsite during construction