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Stages of project implementation

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All KAPELOU projects are well-established business processes with clear implementation stages. The result always depends on the clarity of the work of the groups of specialists responsible for each stage, and the coordination between them.

All of this is systematized over the years of practice, so we take responsibility for all stages – from task definition to service support throughout the life cycle of the system, regardless of the complexity of the project. In general, the project implementation contains 7 main stages.

1. Defining the task and audit

At this stage, company representatives set up meetings with the client in the office at the negotiating table and directly at the facility. Next, the client is provided with a specially designed questionnaire to fill out. During the task definition and audit phase, it is determined which solution will meet the needs of the client. To do this, even at the stage of inquiry or negotiations, KAPELOU organizes reference visits for the client to a warehouse with similar equipment in order to demonstrate its work in action.

This stage provides:

  • collection of information about the client’s field of activity;
  • study and analysis of the work of the client’s warehouse, the flow of goods;
  • definition of goals and required functionality in the warehouse.

2. Development of a conceptual solution

At this stage, the analytical and conceptual department is involved in the work. Conceptologists analyze the characteristics of cargo traffic and processes. Then they model the flow diagrams and calculate key performance indicators for the entire system. All calculations are carried out according to the information collected at the first stage.

The next step is a conceptual drawing of the project, created in a specialized software environment. Based on the collected data, KAPELOU specialists develop a 2D equipment layout and 3D animation of the project in real time. Through the concept drawings, the client can see how his warehouse will work after the project is completed.

3. Detailed designing

The project team works out every element and mechanism of the automation system to the smallest detail. The team includes: designing engineers, electrical engineers, engineers of the APCS department and the installation and service team. They test the operation of the equipment using a digital twin. As a result, the whole system works accurately and smoothly.

At the stage of detailed design, the project is transferred to the project manager. He draws up a calendar time-plan of the project, coordinates all processes, monitors their timely execution. This guarantees round-the-clock customer support at every stage of the project. The advantage is that the client receives answers to all questions from one person. In addition, he clearly knows the whole situation of the project.

4. Production

At its own production, KAPELOU manufactures elements for conveyor systems of any complexity. All parts are produced on German DMG MORI and TRUMPF machines, which ensures accuracy up to 0.01 mm. We buy raw materials from the Netherlands, and components from Germany and other European countries.

Simultaneously with production, specialists develop equipment control software (WCS) so that the entire system works as a single mechanism.

5. Equipment integration

At this stage platforms, mezzanines, rack structures, assembled control panels, KAPELOU conveyor modules, already equipped with electricity and electronics, are installed in the warehouse.

A feature of the KAPELOU approach is that the equipment is completely ready for connection and integration with the WMS warehouse management system. In addition, KAPELOU has its own production facilities for large-unit assembly. The prefabricated structures of conveyor lines, assemblies and units for a wide range of equipment are formed here from the created parts. There is a workshop on assembly of control boards, switchboards on the basis of the production site of KAPELOU. By manufacturing and assembling equipment on our own production capacity, we can guarantee quality and durability by ensuring that the project is completed within the specified time frame.

Years of practice, regular process improvement and professional equipment allow us to install even the most complex systems quickly and in compliance with all standards, and to integrate equipment without stopping the warehouse. KAPELOU has over 590 completed projects in Ukraine, Germany, Bulgaria, Georgia, Belarus, Hungary, Greece, Estonia. Therefore, installation of equipment abroad is a regular practice for us. For foreign projects, our installation team arrives at the site and performs all further commissioning.

6. Commissioning

At this stage, the system begins to work smoothly already at the customer’s warehouse after many hours of work of engineers, installers, IT specialists, analysts, constructors and designers.

KAPELOU engineers set up and test electronics, all mechanisms and individual components. They experience the maximum throughput of the equipment and various scenarios of work. In addition, KAPELOU always conducts training for the client’s employees so that everyone understands their role and works confidently with the automation system. Next, the chief engineer of the client’s warehouse is given the instruction manual, technical passport and drawing.

7. Service 24/7

Technological equipment manufactured by KAPELOU, regular service and compliance with the rules of operation of the system require uninterrupted operation of the customer’s warehouse. KAPELOU provides comprehensive service support throughout the entire life cycle of the system. The first year – under the guarantee, then – under the maintenance agreement.

The well-coordinated work of specialists at each of the seven stages allows KAPELOU to successfully implement project after project. Each of them is unique due to new solutions for Ukraine – buffer sequencer, Speedbot, Unithub and others. Along with this, our client receives everything from one source. Long-term trust of KAPELOU clients, their confidence that we will do it in a quality and within the time frames, motivates our team to implement even more projects and apply non-standard solutions. You can get acquainted with all KAPELOU cases in the “Our projects” section.

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