ABB Schweiz

Retrieval of pallets with assembly sets at the right time

The task of the assembly tool pool at ABB Schweiz is to retrieve tool sets used to build systems all over the world. The power and automation technology group has been using storage and retrieval solutions from Kardex Remstar to do this at its Zurich/Oerlikon site for quite some time. ABB has now ordered two additional Shuttle XP 1000 units for storing entire pallets holding assembly sets. Retrieval performance has improved considerably ever since.

Advantages at a glance

  • Automated storage of pallets with double frame(height of stored goods: 950 mm)
  • Retrieval of assembly sets on time for building sites all over the world
  • Space for 58 pallets on a footprint measuring just 18.94 square meters
  • Nine-meter-high storage units make optimal use of the hall height

The Customer

ABB employs around 6,500 people in Switzerland and focuses on the power and automation technology divisions. Gas-insulated switchgear for power distribution in grids is manufactured at its site in Zurich/Oerlikon. The assembly tool pool supplies tools and materials for assembling new switchgear as well as spare parts for servicing and maintenance. About 1,000 different items are stored in the warehouse, and around 8,000 in total.

Task definition

The ABB Schweiz tool pool has been working with Kardex Remstar storage systems for quite a while. Around 20 automated storage lifts and vertical carousels have been gradually acquired over the years. The individual tools for the assembly sets are stored within them and retrieved at the touch of a button. There used to be bottlenecks with assembly sets that weren’t yet fully picked. Until recently they stood on pallets on static shelving, which gradually led to huge space and maneuvering problems. So when the head of the assembly tool pool received a newsletter from Kardex Remstar about automated pallet storage, the information arrived at just the right time.


Kardex Remstar recommended two Shuttle XP 1000 storage lifts for the space saving storage of pallets with double frames. Pallets with semi-picked tool sets wait in one unit until all the items are available to complete the set. Most of the parts are supplied on a loan basis. They include diamond drill sets, equipment for dealing with faults, repair sets, and high-quality measuring devices. They are returned after use and are initially temporarily stored in the second Shuttle XP 1000. Once the returns have been checked, the items find their way back to the parts warehouse. One of the employees in the assembly tool pool operates one of the two Shuttle XP 1000 storage lifts between 20 and 50 times a day using the touch screen on the control unit. The pallets can be ergonomically moved into position to be picked up by a forklift truck or electric pallet truck with the help of a tray extraction device.

Scope of delivery

  • 2 Shuttle XP 1000 units (W x D x H 1,850 x 1,270 x 8,850 mm) for storing pallets with double frames (height of stored goods: 950 mm)
  • 29 trays
  • OPLogicontrol unit (+ 20 various storage lifts and vertical carousels from Kardex Remstar)