At CERATIZIT’s invitation, we visited its logistics center in Kempten, Germany, where thousands of cutting tools are dispatched to customers worldwide each day. With 90,000 items available for immediate delivery and 400,000 storage locations, the facility illustrates how scale and automation are combined in a tightly controlled logistics operation.
With a floor space of 50,000 m2, the logistics center in Kempten is a key pillar supporting CERATIZIT’s delivery performance. Tools from multiple production sites are received, stored and redistributed to customers across global markets. Around 90,000 different tools are held in stock for direct shipment. The site functions not only as a storage facility, but as a highly organized logistics hub where speed, reliability and process control are closely integrated.
The scale of the operation is significant. Approximately 3,000 parcels leave the facility each day, representing around 18 tonnes of cutting tools. At the same time, inbound goods are continuously received and integrated into the system. To manage this flow, CERATIZIT relies heavily on automation. Tools are already equipped with barcodes at the production stage, enabling immediate identification and handling upon arrival. This forms the foundation of a logistics process in which manual intervention is minimized.
Automated storage
At the core of the logistics center is an automated warehouse system with approximately 400,000 storage locations. Within this system, 270 shuttles transport tools between different stations. Incoming products are automatically assigned to storage locations based on barcode identification, creating a continuous internal flow of goods with minimal intermediate handling.
This approach delivers more than speed alone. By automating storage and internal transport, the system provides a high level of control over availability and traceability. At any moment, the system can determine the exact location and stock level of each item. This is critical in an environment managing tens of thousands of product variants, where delivery reliability depends directly on inventory accuracy.
The high level of automation also supports scalability. CERATIZIT has designed the building to allow relatively straightforward expansion. Space has been reserved to install an identical warehouse system opposite the existing one. This enables future growth in product range, order volumes and shipments without requiring fundamental changes to the logistics structure.
Efficient picking with digital support
Automation is also deeply integrated into the order picking process. Instead of employees moving through the warehouse to collect items, tools are delivered to sorting and packing stations. Operators work from fixed positions while goods are automatically supplied, reducing processing time and minimizing the risk of errors associated with manual searching and handling.
The stations are equipped with a put-to-light system, where light signals and displays guide operators through each step of the process. The system indicates the number of items to pick, their location and the corresponding order. This ensures a fast and consistent picking process. As an additional control, integrated weighing systems automatically verify whether the correct quantity has been processed, providing an extra layer of validation.
The entire operation is supported by SAP Extended Warehouse Management, which is directly connected to the automated warehouse control system. This software forms the digital backbone of the logistics center, enabling both daily operations and broader supply chain digitalization. CERATIZIT expects to further increase automation in the future, including the use of robots for parts of the picking process. The Kempten facility is therefore designed not only for current demand, but also for the next phase of logistics automation.
