Case Study · Digital Transformation of a Warehouse
Digital Transformation of the Automated Stacker-Crane Warehouses at Dukat
Dukat d.d., a member of the Lactalis Group, is the leading manufacturer of dairy products in Croatia. With the aim of further optimizing its logistics processes, Dukat has decided to modernize the management of its high-bay warehouse, which has a capacity of 4,500 pallet spaces.
In this context, AIDA WES has been implemented—Codel’s proprietary platform that connects physical and information flows, manages the equipment of the automated rack storage system, and integrates with SAP, the Infolog WMS system, and production lines.
Project Partners
Lactalis Dukat d.d. is both the user and the client for this solution, while Codel Solutions developed and implemented the AIDA WES system for managing high-rack warehouses and integrating with existing ERP and WMS platforms.
Digital Transformation by the Numbers
4.500
pallet spaces
185 million
kg of milk per year
80+
export markets
3
integrated systems
PROBLEM
Operational Challenge
In the production of dairy products, where shelf lives are short and traceability requirements are high, it was necessary to modernize the management of the high-rack warehouse and integrate warehouse processes with production and business systems into a single, digitally managed whole.
Key Project Requirements
- Automate the receipt and issuance of pallets in a high-bay warehouse
- Integrate the warehouse with SAP, the Infolog WMS system, and the production lines
- Ensure full traceability of serial numbers, best-by dates, and logistics codes
- Enable real-time visualization of warehouse and equipment status
The Importance of the Problem
In the food industry, accuracy, speed, and traceability directly impact delivery quality and product safety. Manual and disconnected processes increase the risk of errors, slow down the flow of goods, and make audits more difficult. A digitally managed warehouse ensures reliable goods flow with continuous monitoring of every logistics unit.
ARCHITECTURE
The Unique AIDA WES Platform
The model is based on Codel’s proprietary AIDA (Automation & Integration Data Architecture) platform. All functionalities are integrated into a single parameter-driven system.
Warehouse Management (HBS)
Complete management of pallet intake and outbound operations using the equipment of an automated rack storage system.
Integration Layer
Automatic transfer of orders from SAP and communication with the Infolog WMS system via XML files.
Logistics Labeling (SIAN)
Printing of logistics labels according to the GS1 standard, with integration with label printers and applicators.
The key component
AIDA WES — Warehouse Execution System
A key component of the solution is Codel’s AIDA WES, a warehouse operations execution system integrated into the infrastructure of an automated high-bay warehouse. It combines warehouse management, integration services, logistics labeling, and traceability into a single, parameter-driven system.
Warehouse Management (VRS)
Comprehensive management of pallet intake and issuance, including automatic and manual assignment of warehousing and issuance tasks.
Integration with SAP and Infolog
Automatic transfer of orders from SAP and communication with the Infolog WMS system via XML files.
Managing Workloads
Automatic transfer of work orders from the production line and assignment of production to IHS palletizers.
Logistics Labeling (SIAN)
Printing of logistics labels based on actual data from the system, with support for GS1 standards.
Tracking and Traceability
Recording of serial numbers and best-by dates, and logging of all operations in the system for analysis and auditing.
Parametric Control System
All functional modules are controlled by parameters in the database, with easy customization of behavior.
COMPARISON
Before and After Implementation
A comparison of existing warehouse processes with the implemented AIDA WES system demonstrates how the integration of an automated warehouse, business systems, and logistics labeling is transforming the structure of work in the logistics environment.
Warehouse Management
Before implementation
The loading and unloading of pallets relied on manual and partially automated steps, with a higher risk of errors.
After implementation
AIDA WES automatically manages the receipt and issuance of pallets using its automated warehouse equipment.
Integration with Business Systems
Before implementation
Orders and data were transferred separately, with manual reconciliation between the systems.
After implementation
Automatic transfer of orders from SAP and data exchange with Infolog WMS via XML files.
Logistics Labeling
Before implementation
Printing and labeling of pallets without a complete link to actual data from the system.
After implementation
AIDA SIAN prints GS1 labels based on actual data, with automatic pallet labeling.
Traceability and Best-By Date
Before implementation
Limited records regarding series and duration made analysis and review difficult.
After implementation
A complete record of serial numbers, best-by dates, and all operations in the system.
Emergencies
Before implementation
Troubleshooting equipment malfunctions and errors required several manual steps.
After implementation
Special tools for managing operating statuses, resetting errors, and visually monitoring downtime.
Real-Time Visibility
Before implementation
Limited visibility into inventory levels and equipment status during a shift.
After implementation
Real-time visualization of warehouse and equipment status, including a 3D view of locations.
PROCESS
Operational Process
The process is designed to minimize manual handling, speed up the flow of goods, and ensure continuous control over every logistics unit.
01 - Task Receipt
Automatic transfers from SAP and the production lines are loaded and routed to the IHS palletizers.
02 - Putaway
AIDA WES assigns pallet-loading tasks and manages the equipment in the automated high-bay warehouse.
03 - Labelling
AIDA SIAN prints GS1 labels, and the system records batch numbers, best-by dates, and all operations for traceability.
04 - Delivery
Pallets are issued based on orders, with data exchanged with Infolog WMS via XML.
Results
Key Operational Effects
The implementation of the AIDA WES system has integrated physical and information flows, reduced operational errors, and laid the foundation for further automation and process optimization.
Related Flows
Physical and information flows are integrated into a single, digitally managed system.
Greater Warehouse Efficiency
Automated management of pallets and equipment speeds up the flow of goods through the warehouse.
Full traceability
Records of the batch, expiration date, and all operations enable easy analysis and auditing.
The Foundation for Robotization
A digitally managed warehouse lays the foundation for further automation and process optimization.
Conclusion
What does the case study confirm?
The implementation of the AIDA WES system at Dukat represents the modernization and digital transformation of logistics in the food industry. The system integrates physical and information flows, reduces operational errors, and increases warehouse efficiency.
The solution developed and implemented by Codel demonstrates that the integration of an automated warehouse with SAP and Infolog, along with full traceability, creates a reliable foundation for further robotization and Industry 4.0 processes.