Scavolini, first manufacturer of kitchens in Italy

Founded in 1961, Scavolini is now the first kitchens manufacturer in the Italian market. In 2000, due to the high production volume reached, Scavolini entrusted GD Convey Italy (GD Convey branch) the engineering, manufacture and installation of its new logistics processes in its Pesaro plant (Italy). This automation required an investment of 6 million Euros.
The solution carried out performs the order picking of complete kitchens to all its clients worldwide, including the furniture and electrical appliance –that Scavolini manages itself to the final client.

Results reached by the new process include:
· Two ABB robots for furniture automatic pallettising in different sizes and shapes, carried out by means of an expert system
  which decides in real time the products palletising mosaic.
· Optimization of the collection, storage and expedition of its products, and for that, an automatic warehouse with seven   machines for 11.500 pallets is integrated. The installation also includes several kilometres of roller, chain conveyors and
  eight shuttle cars.
· Racionalization of the plant by installing 2 levels, the lower one used for carrying the trucks in the fewest time and so
  leaving the floor space free and the upper level for production and warehousing.
· Improvement of operators' ergonomics and working conditions.
· Tracking of each tray from each part of the plant – automatic warehouse, shuttle car warehouse, production lines, gravity
  lines-, forming the order by multiple trays and objects, even those being transported in a consequential sequence in order
  to fill the truck in the most convenient way, for instance, last orders and heavy objects.

In 2007, the innovative solution introduced by GD Convey is the integration of an inverted monorail in connexion between the new warehouse and the order fulfillment area. The inverted monorail enables to maintain the flow in just one floor in high throughput situations.

The new installation consists of the following sub-systems:
An automatic high bay warehouse for 16.300 positions and 4 stacker cranes.
An inverted monorail, which is the backbone of the system which links the several areas by shuttle cars.
An intermediate buffer that manages high density references.
Pick up area automation.
Warehouse input/output by means of pallets conveyors.
ConveyWMS and SCADA System.