viastore modernizes DACHSER warehouse in Herne

The automated high-bay warehouse of logistics service provider DACHSER in Herne has been in operation for 35 years. Over time, the storage and retrieval machines, as well as the conveyor technology, became outdated, and the IT infrastructure grew inconsistent and obsolete, posing a high risk of failure. To address these issues, DACHSER commissioned viastore as the general contractor for a comprehensive and complex retrofit. The first milestone was achieved at the end of 2024 with the launch of a new control system and the viadat warehouse management system.

Founded 94 years ago as a freight forwarding company, DACHSER SE has evolved into an international logistics service provider with nearly 19,000 employees. Headquartered in Kempten, Bavaria, the company operates 72 locations worldwide and handled approximately 39 million shipments in 2023. A reliable infrastructure is crucial for such performance, which was no longer the case for the automated high-bay warehouse at DACHSER's Herne site in North Rhine-Westphalia. The nine pallet storage and retrieval machines (SRMs) and the conveyor technology had been in use for 35 years, and the IT infrastructure had grown over time. The knowledge of the custom-built warehouse management system was limited to a few employees nearing retirement, increasing the risk of system failure.

In May 2023, DACHSER engaged viastore as the general contractor for a retrofit. This project included modernizing the SRMs and conveyor technology, renewing the conveyor control system, introducing the viadat warehouse management system, implementing the viavision system monitoring tool, and integrating the IT with DACHSER's higher-level MIKADO customer system—all while maintaining ongoing operations.

After 18 intensive test weekends, during which the viastore team decoupled the existing PLC and WMS and connected the system to the new infrastructure by Sunday evening, the go-live occurred in mid-November. "It went smoothly, and the automated warehouse is running at full capacity," said Jochen Rettig, Senior Project Manager at viastore. "The next steps include expanding the pallet conveyor system, incorporating safety technology, and modernizing the nine storage and retrieval machines. We expect to complete the project by September 2025."