Automated Logistics Expansion at Liebherr Ehingen

Liebherr-Werk Ehingen GmbH has commissioned Jungheinrich to expand the automated logistics system at its Ehingen production site. The project focuses on increasing order-picking capacity and improving material supply reliability for crane production and global spare-parts distribution.

Scaling logistics capacity for spare-parts supply
The expansion includes the conversion of two existing order-picking workstations and the addition of four new goods-to-person service centre (GSC) workstations. These stations automatically supply containers and pallets with short access times, supporting a continuous and predictable material flow. The design emphasizes ergonomic operation, reducing manual handling while maintaining high process stability.

By integrating the new workstations into the existing pallet and container conveyor infrastructure, Liebherr increases overall system throughput. Each line is designed to handle up to 120 pallets per hour, providing the capacity required to support growing spare-parts demand across global markets.

Technical scope and system integration
Jungheinrich is acting as general contractor for the project, covering mechanical modifications, conveyor system expansion, and full software integration. The additional workstations are being incorporated into the existing Jungheinrich warehouse management system (WMS), ensuring consistent control logic, inventory transparency, and coordinated material flows across the facility.

A key technical element is the adaptation of Liebherr’s virtual test environment. This digital system allows realistic simulation of the expanded logistics setup before commissioning. By validating material flows, workstation behavior, and software interactions in advance, the approach reduces ramp-up risk and supports a smooth transition into live operation.

Focus on reliability, ergonomics, and future-proofing
For Liebherr, the logistics upgrade addresses multiple operational requirements simultaneously. Automated goods-to-person processes reduce picking times and operator strain while maintaining high accuracy. The modular expansion approach also allows further scaling without fundamental changes to the existing infrastructure.

The project reflects a broader trend in industrial manufacturing toward highly automated, software-integrated intralogistics systems. By combining conveyor automation, workstation ergonomics, and WMS-driven control, Liebherr is reinforcing its ability to deliver spare parts reliably while preparing its logistics operations for continued growth.