Maurer Electronic GmbH, based in Uttenweiler, Baden-Württemberg, is a system and component supplier for custom cable assemblies, assemblies, control cabinets and other electrical engineering solutions. With the construction of a new facility and the centralization of its value creation, the company laid the foundation for expanding production capacities and reorganizing its material supply. The focus was not on additional storage space, but on a reliable, clearly structured and cost-effective supply for production. Around 15,000 different items, ranging from miniature circuit breakers to complex control units, place high demands on availability, handling and process reliability.
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The choice fell on the STOROJET automated storage and retrieval system (AS/RS) because it is tailored to the requirements of production. Different load carrier formats and flexible compartment layouts allow a wide variety of materials to be stored in a space-saving and clearly organized way. At the same time, the system helps increase the degree of digitalization in material supply.
The available space is used efficiently: across a footprint of 320.5 m², more than 15 levels create around 1,635 m² of net storage space. The system operates with four lifts and 84 robots up to a height of 6.98 m. Currently, 5,160 trays with a total of 19,896 compartments are in use. Load carriers in the 500 × 600 mm and 500 × 900 mm formats, combined with flexible compartment layouts, make it possible to use carton heights efficiently and maximize storage capacity right up to the ceiling.
Under normal operating conditions, the automated storage and retrieval system (AS/RS) achieves up to five load carrier presentations per minute at each port. In Maurer’s specific application, however, the focus is not on maximum throughput, but on production-oriented material provision.
Production orders generate pick lists, which in turn trigger transport orders sorted by BMK. Sequence and consolidation are aligned directly with the requirements of downstream processes. This ensures that all materials are assembled order by order and provided in a structured way.
The key advantage is that materials are available at the right time and in the right sequence. Search times are eliminated, processes become more stable, and production can operate more efficiently.
In day-to-day operations, the system stands out through intuitive port operation and clearly structured processes. New materials can be stored quickly and easily thanks to the flexible design of the load carriers.
The underlying goods-to-person principle reduces walking distances during storage and retrieval, improves ergonomics and supports predictable day-to-day warehouse processes.
The impact is clearly visible in daily operations: with half the staff, twice as much is now picked. At the same time, work can be distributed more flexibly.
Material supply has also improved significantly. Around 95 percent of material movements are handled via the warehouse, the majority of them through the automated storage and retrieval system (AS/RS). Materials are consolidated and delivered directly to the respective areas. This reduces travel distances, saves time and improves responsiveness in shortage management.
In addition, optimized batch traceability provides greater transparency. Materials can be clearly assigned to individual suppliers and production orders. This strengthens traceability, improves process quality and supports a higher overall level of digitalization in material supply.
The pick-by-light system supports employees in carrying out reliable bookings and reduces errors. Visual guidance ensures clear material assignment, especially in order-related picking. Freely configurable ports provide additional flexibility and enable targeted handling of special cases such as missing parts or inspection processes.
Alongside performance, availability is a key advantage of the system. With a system availability of 99.95 percent, a reliable material supply is ensured at all times. This creates stable conditions for supplying production and supports a high level of process reliability in day-to-day operations.
In addition, Maurer Electronic uses Zebra back-of-hand scanners, which support ergonomic and efficient working. They are easy and intuitive to use, keep both hands free during work and ensure reliable scanning. Industrial and label printers from the same manufacturer are also in use and support stable day-to-day processes.
In addition to the technology itself, the collaboration with Storojet GmbH is also viewed positively. In particular, support during ongoing operations is highlighted as reliable and solution-oriented, which is an important factor for systems that are deeply integrated into production supply.
With STOROJET, Maurer Electronic has not simply automated a warehouse, but restructured its entire material supply. What matters here is not a single performance figure, but production-oriented sequencing, consolidated material provision and a high level of process reliability. The automated storage and retrieval system (AS/RS) combines a wide range of items with stable, efficient processes, making it a key building block for a high-performance and future-ready production environment.
| Height: | 7 m (plus 1 m for the lifts) |
| Levels: | 15 (clearance 400 mm) |
| Footprint: | 320 m2 |
| Highspeed Lifts: | 4 |
| Robots: | 84 |
| 500x600 mm (WxD): | 4.578 |
| 500x900 mm (WxD): | 582 |
| Storage and retrieval | 4 |
| Daily operating time: | 8 hours |
| Picks*/Hour per Port: | 150 |
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