KNAPP has rolled out a comprehensive automation solution for SICK’s manufacturing site in Kunsziget, Hungary, deepening the long-standing technology partnership between the two companies. The project introduces Open Shuttle autonomous mobile robots and an automated small-parts warehouse, all integrated through an end-to-end SAP® EWM by KNAPP system, to streamline internal logistics and boost production efficiency.

SICK, a global leader in sensor technology, recently expanded its Kunsziget plant with three new halls dedicated to goods-in, manufacturing and small-parts storage. KNAPP’s automation links all areas of the facility, ensuring seamless goods flow and supporting SICK’s strategy for future growth.

“One of the major advantages is that the system is geared towards the future, with capacity for today as well as tomorrow. We made it possible with the logistics support of KNAPP,” says Laszlo Varga, Supply Chain Manager at SICK Kft.

At the core of the new setup are 27 Open Shuttles that transport containers between the automated warehouse and four manufacturing halls, enabling just-in-time delivery, reduced inventories and optimized material movement. The automated small-parts warehouse features a stacker crane serving 52,000 locations across four aisles, supported by goods-to-person picking at two Pick-it-Easy workstations. A ceiling-mounted conveyor system connects goods-in directly to storage, completing a fully automated, space-efficient logistics loop.

The entire operation is orchestrated through decentralized SAP® EWM on S/4HANA, which functions as both the warehouse management and control system. Integrated with KiSoft Fleet Control and connected via REST interfaces, the system manages complex storage strategies, production supply methods and real-time task allocation. KNAPP and SICK jointly prepared for the rollout through a pilot project that also trained SICK’s IT team on the new digital processes.

The deployment marks another milestone in the companies’ collaboration, with SICK’s own sensors powering all automation components in the upgraded facility. The system has been designed with scalability in mind, allowing additional manufacturing halls to be integrated as production demands increase.

Solution Highlights

• 27 Open Shuttle AMRs for direct production supply

• Automated small-parts warehouse with 52,000 storage locations

• 22 supply and 8 putaway flow racks across the production area

• Pick-it-Easy workstations and goods-in stations

• Ceiling-suspended and spiral conveyors for seamless goods flow

• SAP® EWM on S/4HANA serving as WMS and WCS for full end-to-end control