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Tillamook County Creamery Association, Oregon invests in $23million expansion
Technology Category
- Automation & Control - Programmable Logic Controllers (PLC)
- Functional Applications - Warehouse Management Systems (WMS)
Applicable Industries
- Food & Beverage
Applicable Functions
- Warehouse & Inventory Management
Use Cases
- Inventory Management
- Predictive Maintenance
- Warehouse Automation
Services
- System Integration
- Training
The Challenge
Operating since April 2000, the Automated Storage and Retrieval System (AS/RS) was upgraded in 2007 by Westfalia, to keep up with advances in technology. The improvements included upgrades to the facility’s Storage/ Retrieval Machine (S/RM), programmable logic code (PLC) and new drive and positioning technology. While the existing AS/RS performed as required, Tillamook’s sales growth was placing increasing demands on their system. Once they became aware that advances in technology could improve the AS/ RS operations, Tillamook decided to upgrade their automated warehouse. Upgrading the S/RM controls would make it work faster, and smoother. Updating the WMS would improve the speed, accuracy and reliability of the warehouse product flows. Tillamook’s automated warehouse is 12-levels, 66 ft. high and holds 15,040 pallet positions to hold 35 million lbs. of block cheese and finished products. A wall divides the facility into two sections, with 40 lbs. blocks stored on the north side, and finished products stored on the south side.
About The Customer
Tillamook County Creamery Association (TCCA) is a renowned dairy cooperative based in Oregon, USA. Established in 1909, TCCA has grown to become one of the leading producers of dairy products in the United States, known for its high-quality cheese, ice cream, and other dairy products. The cooperative is owned by nearly 80 farming families, who are dedicated to sustainable farming practices and producing the best possible dairy products. TCCA operates a state-of-the-art production facility that includes an automated warehouse system to manage its extensive inventory of dairy products. The cooperative has a strong commitment to innovation and continuous improvement, which has helped it maintain its competitive edge in the market. With a focus on customer satisfaction and product quality, TCCA has built a loyal customer base and a strong brand reputation over the years.
The Solution
As part of the AS/RS upgrades, the controls on the S/RM were replaced with an Allen-Bradley ControlLogix solution, which can be accessed remotely via VPN for easier troubleshooting by Westfalia’s Service Department. Horizontal and vertical drive systems were upgraded to SEW Eurodrive, while mechanical encoder positioning devices were replaced with a SICK laser positioning system on the horizontal and vertical axis. Westfalia’s Warehouse Management System (WMS) controls and optimizes the product flows throughout the facility. Products are tracked by bar code for easy identification and pallet storage. This results in a controlled, paperless environment that coordinates order picking and processing with the host computer. Westfalia’s WMS at Tillamook, a predecessor of our recent Savanna.NET® WMS, has proven its ease of use, reducing training time, and resulting in faster more efficient product flows. Westfalia updated the communication infrastructure between the S/RM, Warehouse Management System (WMS) and Conveyor System, replacing an infrared and a second hardwired interface with a Wireless LAN, thereby eliminating electrical interference issues due to mechanical wear. In addition, all conveyor PLC and WMS communication interfaces have been brought up to the most recent Westfalia standard.
Operational Impact
Quantitative Benefit
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