Centrotherm shortens warehouse closure from four to one day during stocktaking

Complete stocktaking in just one shift: Centrotherm, a company based in Brilon, Germany, known as a developer, manufacturer and distributor of gas flue systems for condensing boilers, has already relied on sample stocktaking in the past. With REMIRA, however, Centrotherm was able to reduce the counting effort even further: Their SaaS software STATCONTROL Cloud in combination with a counting app ensured greatly reduced warehouse closing times at Centrotherm. 

Centrotherm Systemtechnik GmbH from Brilon develops, manufactures and sells innovative plastic and gas flue systems for condensing boiler technology, among other things. The product range also includes solutions and products for the ventilation and automotive industries. The company is represented by sister companies and subsidiaries in all core EU countries as well as in the USA and China. Around 230 employees work at the headquarters in Brilon. Centrotherm had already been using a sample stocktaking system in the main warehouse for several years, but still had to close the warehouse for four days every time a stocktaking was carried out.

The aim was to expand this procedure based on the good experience with sample stocktaking in one part of the warehouse - including in a new warehouse. Centrotherm turned to REMIRA because the company was already familiar with their contact person from previous projects. In a joint workshop, the optimization potential of the stocktaking was then worked out and an implementation strategy developed. “We also put all warehouse areas and their inventories to the test in Brilon. In addition to the new STATCONTROL Cloud, we were also introduced to the corresponding counting app. The subsequent test inventories produced very good results, which is why we then decided to use STATCONTROL Cloud and based our stocktaking concept on this and the newly developed counting app,” recalls Dr. Raino Rieseler, Managing Director of Centrotherm. His colleague, Frank Engelbracht, Head of Finance, adds:

“To give us an overview, we had written to several service providers. Right from the start, the information we received and the coordination with REMIRA were very professional. As a result, it very quickly became clear that we would continue with REMIRA.”

1% counting effort in the new narrow-aisle warehouse

Just two months after the test stocktaking, the live process started in Brilon in December 2022. A total of three warehouses were inventoried using the REMIRA SaaS solution and the counting app on tablets. Despite the previous sample stocktaking in the main warehouse, the effort involved has now been reduced by a further 90%. One of the warehouses inventoried with STATCONTROL Cloud, a narrow-aisle warehouse, had only recently been completed. Out of 3,225 items, only 39 samples determined by the software had to be counted - this corresponds to only around one percent of the counting effort. For Centrotherm, the switch to STATCONTROL Cloud was an enormous relief. Very high production requirements demanded maximum utilization of the machines - closing the warehouse for four days to take stocktaking was therefore a huge setback. In addition, many employees were involved in the counting process and were absent from production. Rieseler:

“Through discussions with REMIRA, we realized that there was still room for improvement. We looked at all the warehouse parts and considered which processes we could best apply to which warehouse parts in order to reduce production downtime. In the end, we are now at around one day of production downtime - we have basically exceeded our target.”

Mobile counting app and cloud solution for fast stocktaking

REMIRA's SaaS solution does not require implementation or consulting, but in individual cases it can be used to identify further potential - as in the case of Centrotherm.

  The system is basically ready to go in just ten minutes thanks to the initial registration process and setting up the necessary users. The user is then guided step by step through the intuitive application. In conjunction with the counting app, counting is carried out directly on mobile devices, which further reduces the time required and the error rate. Frank Engelbracht also found the flexibility of the new solution and the various stocktaking procedures to be major plus points: For example, a high-count method was used in the main warehouse and a sequential test was carried out in the new semi-automatic warehouse. Frank Engelbracht:

“In addition, we were able to avoid a lot of the paperwork by using the counting app. It has also enabled us to reduce the input of counting lists to a minimum. In the past, two employees were required to enter counting lists for each shift. This will no longer be necessary in future, as everything will be handled via the existing interfaces.”

He also praised the intuitive user guidance in the STATCONTROL Cloud and the counting app as well as the free parameterization of the setting options. Centrotherm always had an overview of all important information as well as the current status, deviations etc. during the entire stocktaking. The counting app also made it easy to initiate recounts in the event of any deviations.

“Do we have to count anything else?”

This question was asked during the stocktaking and the answer was: “No.” Due to the innovations and changes, Centrotherm had - in retrospect - scheduled too many employees for the stocktaking to be on the safe side. In the end, the counting process was completed by one shift and the newly added employees were 'unemployed' with regard to the counting process.

“We found the collaboration with REMIRA to be very professional, collegial and pleasant. We will also be using the STATCONTROL Cloud sample stocktaking software next winter - but we will be able to schedule significantly fewer employees and reduce the shifts from eight to six hours, which will have a positive effect on both counting quality and concentration.”

says Frank Engelbracht. The first workshops for extensions have already been requested and the employees are also much more relaxed about the next stocktake than before. A colleague from Centrotherm summarized the experience with STATCONTROL Cloud as follows:

“Best stocktaking ever!”