Spare parts warehouse

MTU America (previsously traded as Tognum) is a leading manufacturer of large diesel and gas engines and propulsion systems. Owing to the worldwide synchronization of the company's after-sales activities and changes in the distribution network, MTU America required a new spare parts distribution center for North America. The new facilities, spanning 32,500 sqm, were established in Brownstown, MI (USA), and planned in cooperation with io-consultants.

Project challenge

A key requirement was to ensure that spare parts are delivered to MTU diesel engine users in North America and across the world within a period of one to three days. The company's global strategy for spare parts logistics is to use uniform systems and processes the world over. Consequently, the new order processing system was designed to ensure that any given product is dispatched using the same procedure irrespective of whether the order is processed in Michigan (USA), Germany or Asia.

io-consultants' task was to simulate a supply chain network, based on the new requirements, that would ultimately determine the new warehouse location. After providing the blueprint planning and a detailed design, the io-consultants team supported MTU America in all the subsequent phases from supplier selection to implementation, the relocation process, and operational start-up.

Newbuild of spare parts warehouse from concept planning to implementation and standard operations

Logistics planning

Brownstown, MI

Customer value

The plant handles 40,000 warehouse items, and is optionally upgradeable to 80,000 parts. The system processes 360 picks per hour in normal conditions. Construction of the new warehouse and operational start-up were completed within a mere nine months. A miniload stacker system with 22,500 storage containers is located near the incoming goods area and uses an extremely quiet conveyor system to dispatch the containers to five ergonomically designed goods-to-person work stations with light-controlled picking functionality. Such goods-to-person systems save the workers a lot of toing and froing as well as reducing the number of required conveyor devices.

Please contact us 

Ansprechpartner USA: Rupert Hoecherl
Rupert Hoecherl President / Partner Phone: +1 (610) 8073590-504