In order to provide faster deliveries to the replacement sector in Brazil, ZF Aftermarket has started installing a new fully automated sorting conveyor at its Distribution Center located in Itu, SP.The equipment, also called a "sorter," is used to classify and separate products based on specific criteria, such as destination, route, or customer orders. The main function of the new sorting conveyor is to streamline and optimize the flow of parts, ensuring that the right products are directed to the correct destinations more efficiently and 30% faster. "This technology will provide a significant improvement in the speed and accuracy of the parts distribution process, contributing to a more efficient operation for our customers," says Bruno Silva, senior operations manager at ZF Aftermarket.
According to the executive, the new resource is gradually expanding its capacity and is expected to reach its full operating potential by the end of this year.
The new equipment is installed in an area of 300 square meters and is intended for 85% of the parts stored in the Distribution Center (DC), since parts of larger sizes and weighing over 11 kilograms are not included in this process, such as transmissions and axles. Currently, the Itu warehouse stores a total of 23,000 items from the brands ZF, Lemförder, Sachs, Varga, and TRW. The company has one of the largest operations in the replacement market in Brazil, handling approximately five million auto parts monthly. It is important to mention that this number does not include the volume handled by the WABCO brand, also owned by ZF Aftermarket, whose parts distribution center is located in Campinas, SP.
The new sorter was entirely developed in Brazil after months of research. These surveys referenced the largest logistics players operating in the country. After evaluating the equipment in operation, ZF decided to import part of the equipment to prevent parts from accumulating as they pass through the curve of the sorting conveyor, correcting imperfections of existing conveyors in the country and providing even greater agility to the process.
For the operation, four tugs are used to feed the sorter. When it reaches its full capacity, the new sorting conveyor will be able to classify three thousand volumes per hour, meeting a daily need to move twenty thousand volumes in a shift, which will all be directed to the spare parts replacement market. With this, the operation will be optimized by more than 30% to meet the growing demand for parts, both from the domestic and international markets.
All sorter movements are guided by product barcodes, ensuring efficiency and accuracy. According to Bruno, all employees have been trained to operate with the new system. "The new line is flexible and allows adjustments to meet different logistics requirements. There is complete reliability in the new process, which includes two types of automated checks, in addition to being integrated with the RFID – Radio Frequency Identification system," explains the executive. With this, the labels attached to the packaging allow the products to be tracked throughout the entire replenishment chain.
“Digitalization has profoundly transformed ZF Aftermarket’s logistics operations and, in addition to agility, has brought intelligence, operational efficiency and a greater capacity to respond quickly to challenges and changes in the market,” he concludes.
