Starting point
The TGW warehouse mechanics were fine. Controls and software were not: outdated, hard to maintain and without a solid MES, WMS and ERP base.
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CASE STUDY · BROWNFIELD · AS/RS
Existing assets. New performance.
PROJECT OUTCOME
Seven-figure capital purchase avoided.
Modernization of a TGW automated small-parts warehouse (AS/RS): Siemens SIMATIC and visualization plus MES, WMS and ERP – built by us. Mechanics and conveyors stayed in place.
System
01AS/RS · TGW
Scope
02PLC, HMI, MES, WMS, ERP, documentation
Technologies
03Siemens SIMATIC · MES · WMS · ERP
Outcome
04Warehouse hardware retained · software base rebuilt
Starting point
In operation was a TGW automated small-parts warehouse (AS/RS). Racks, conveyors and mechanics still ran reliably – the control and software base did not: outdated, hard to maintain and barely connectable to MES or ERP systems. Replacing the entire warehouse would have meant seven-figure capital spend. The goal was full modernization in place – including the operational systems above the controls.
- TGW AS/RS: mechanics and conveyors intact
- Control and software stack obsolete
- No viable MES / WMS / ERP layer
- Goal: modernize in place instead of full replacement
Project stages
Implementation
Migration to Siemens SIMATIC, new visualization, development of MES, WMS and ERP plus full technical documentation – AS/RS and mechanics stayed in service.
Result
The AS/RS stayed online. Controls, MES, WMS and ERP work as one stack – extendable and integrable, without a seven-figure warehouse replacement.
What we delivered
Siemens SIMATIC
Migration of the AS/RS control system onto a current SIMATIC base – structured, documented and integration-ready.
Visualization
New HMI and plant visualization for warehouse operation – clear, maintainable and extendable.
MES & WMS
Custom manufacturing execution and warehouse management – orders, stock, movements and shop floor in one continuous system.
ERP
Custom ERP for sales, order handling and commercial processes – connected to manufacturing and warehouse.
Technical documentation
Full documentation of controls, interfaces and operational software – for operations and future work.
Warehouse hardware retained
TGW mechanics and conveyors stayed. We modernized and rebuilt the software base – not the substance that still carried the system.
Results at a glance
AS/RS in operation
No unnecessary capital replacement. The existing TGW warehouse hardware continues to carry operations.
Modern control base
Siemens SIMATIC and current visualization instead of outdated, person-dependent software.
MES, WMS and ERP from one team
Production, warehouse and business workflows run on software we built for the operation.
Ready to scale
Further automation and integration are plannable on the new base – without restarting the AS/RS.
Modernize brownfield – without sacrificing operations.
This project shows what full in-place modernization can deliver: renew AS/RS controls, build MES, WMS and ERP, restore documentation – and keep the TGW mechanics that still carry the warehouse. If your storage or production system is outgrowing its software base, we build the migration path.