Danfoss Solar Inverters - distribution and production layout

15-08-2011

Danfoss Solar Inverters, whose UniLynx and TripleLynx inverters are used in private as well as commercial solar energy systems, for the transformation of solar energy to electric power, has experienced a pronounced increase in the demand for their products; a situation which has pressed the production in Gråsten and Sønderborg to the utmost.

Inverter production moves to Nordborg

As Danfoss has a defined strategy to be an important player on the global market the company decided, in the summer 2010, to move the inverter production to Danfoss’ headquarters in Nordborg. To expedite the launch of the new production premises scheduled for the second quarter of 2011, Danfoss chose to fit the production into some of the existing facilities.

Data analyses and interviews as basis

The strategic importance of the project and the forced times plan underlay Danfoss’ decision to involve Langebæk Logistik. Initially, the assignment was to design the logistics around the future production and distribution of the Solar Inverters products and to design a master plan for the realisation of the recommended solution.

Langebæk Logistik began the preliminary analysis in August 2010. Then followed diverse activities such as:

• Interviews with key employees
• Recording of material, products, information and workflow
• Data collection and estimation in relation to incoming goods, stock volume, stock utilisation, order volume, product range, master data and shipping.

On that basis, the requirements to the new facilities and to the dynamic capacity, order structure etc. were defined, leading to the development of the optimum logistics concept, which Langebæk presented after six weeks of intensive work.

Goods reception in basement	Goods supply for production

Close cooperation with project team

After the definition of the overall logistics solution, Danfoss Solar Inverters operations requested Langebæk Logistik to also assist Danfoss’ project team with the project design of the assembly related part of the assignment and with the subsequent implementation of the solution. Danfoss’ reason for extending the cooperation was to ensure optimum flows in the production, cost efficient consolidation and a reduction of non-productive material / goods handling to obtain competitive product flows with low unit costs.

Solution concept

The logistics and the assembly concepts included layout proposals, estimation of alternative solution designs, recommended routines for material and goods handling, recommended technology (automation) and a detailed plan for the realisation of the solution.

Project design

The project design took place in the fall and required a very thorough detail specification of the required equipment. The supply was subsequently put out to tender among relevant suppliers selected by Danfoss Solar Inverters and Langebæk Logistik between them.

Implementation

Danfoss Solar Inverters own project team has handled the project implementation and the realisation with sparring and support from Langebæk Logistik. The implementation was initiated even before the complete supplier selection and speeded up in February 2011. During this part of the project, Langebæk Logistik has currently modified the solution and supported the installation of the technical equipment.

Launch

The production is expected to be fully operational in August 2011.

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