The increasing demand for bespoke products can put added strain at every level in the supply chain. Timber merchants, board distributors, panel processors and joinery companies are all likely to be holding stocks of an ever wider variety of materials, making efficient storage, retrieval and control of such rising stock levels challenging.

Recognising the need for a cost-effective solution, BARGSTEDT, part of the Homag Group, has developed the BARGSTEDT TLF 210 automated board stock control system.

The concept behind the TLF 210 is to maximise productivity and minimise downtime. It has proved a real money saver for small and large companies specialising in low batch, make-to-order production that use a variety of board types, colours and sizes.

Simon Brooks, sales and marketing director for Homag UK, said not only does the TLF 210 reduce the floor area required for stock, but it also improves the yield from the saw or CNC that it feeds.

"The yields are improved because it is the system’s software that controls the output from the machines and not the machine operatives. Traditionally, you have had to rely on the operators to keep feeding the machines at the ideal rate; the TLF 210, however, automatically feeds the machines at the optimum rate without fail, day in, day out," he said.

The BARGSTEDT system gives customers complete control of their stocking and cutting requirements. "This means they only need to cut what they want, when they want it. Naturally, this dramatically reduces the amount of work in progress that historically would have ended up sitting on a factory floor," said Mr Brooks.

The TLF 210 can be used as a stand-alone stock management system. It can automatically create rainbow stacks for delivery to separate factories – a great tool for board suppliers, according to Mr Brooks – or it can be combined with, and completely integrated into, a production cell.

"The system is perfect for sizing panels using a Holzma beam saw or for nesting boards using Homag or Weeke CNC routing systems. The TLF 210 can even feed multiple saws and routers in the same cell," said Mr Brooks.

The heart of the system is BARGSTEDT’s IntelliStore software which controls the whole system and is used to manage stock control and to replenish and optimise the stock levels. The IntelliStore control registers the complete material stock and calculates the optimal material flow according to daily production requirements.

"It is very easy to use," said Mr Brooks.

"Each board type has its own ID number and once this is entered into the system, no manual intervention is required. Optimised material cutting plans are transferred from the office directly to the BARGSTEDT system and it automatically picks the required products in the chosen sequence and feeds them to the saw or nesting CNC, or both, at exactly the right time.

"While the sizing machine converts the board into the required parts, IntelliStore continues to manage stock. It sources the next job that is required and delivers it to the saw or router before the cutting cycle is completed, providing total efficiency."

Automatic sorting
All the sorting of board materials to optimise the daily work schedule is performed automatically in a greatly condensed floor space.

"No fork trucks or operators are required to move boards around the factory or to dig out that one-off board that always seems to be at the bottom of a stack," said Mr Brooks.

"IntelliStore can even operate under ‘lights out’ conditions, meaning the system can earn you money while you enjoy your free time."

Paul Watson, managing director of SW Watson, a Preston shopfitting and office furniture manufacturer, is a convert.

"A few years ago it was unthinkable that a company our size would be able to invest in such an automated system. Now it’s within reach of most manufacturers and there’s no doubt in my mind that in the next 5-10 years, unless you have automated systems like this, you will not be able to survive," he said.

"It wasn’t until I saw the TLF 210 storage system actually working in Germany that I fully realised the potential for our business. And, although we only had it installed in mid-2012, it is clear that the BARGSTEDT/HOLZMA combination has revolutionised our production process."

Key Benefits of BARGSTEDT TLF210

  • Tight control of material stock levels
  • Automatic stock replenishment process
  • Much reduced floor space requirements for board storage
  • Reduced work in progress requirements
  • Improved machine efficiencies
  • Reduced labour
  • Extreme flexibility
  • Efficient and automatic selection of one-off products
  • Automatic off-cut management
  • Reduced material damage
  • No manual handling