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ERCO, Lüdenscheid ERCO Campus & P3




laser machine

neon glow lamps


LED technology


BIX “big pixels”



LED pixels


hanging LED curtains

touch technology


weapon of choice

t i me

Lighting Context



Light Shows

scenic effects


Las Vegas Strip

from competing di fferentiated businesses businesses from competing businesses


Tokyo Billboards The Kunsthaus Graz Built in 2003


2001 Schneider + Schumacher

content dibrand fferentiated product and brand content

fferentiated di fferentiated di fferentiated buildings from context buildings

driving / walking



Port Authority Bus Terminal

A.AMP Building Singapore

buildings di fferentiated ( + formally) buildings & content



retrofitted buildings

immersive experience



Märkischer Kreis

North Rhine-Westphalia

Warehousing Context Multiple Suppliers

86.73 km² Population: 78,032 Industry: Aluminium processing Automobile industry Electrical and lighting Mechanical engineering Tool manufacture

Land Distrubution: 47.4% forests 22.4% agriculture 2.5% other land 18.1% buildings/open space 7.3% traffic area 2.3% water

ERCO, founded 1934 Evolved from a lamp factory to a system supplier for lighting, not only components such as lights, lamps, wiring devices, bus bars, etc. but also lighting systems for buildings and urban landscapes. Develops and delivers the associated light control systems. Prom inent position on the world market.

LED Tubes

Plants broken goods discarded LED Tubes P1


LED Tubes

ERCO Plant

ERCO plant , warehouse Ludenscheid , Germany




P1, P2, P3

goods sorts into one of the three facilities at ERCO plant

Delivery Zone

goods are automatically unloaded from trucks transported to prestorage

Automatic Storage robotics automatically pallets goods and store to specific shelf

Automatic Retrieval the as/rs system utilizes the automatic crane to retrieve products and bring products to be shipped out

Distributors products either converyored to P1 plant or sent to the retrieval docks to ship to distributors


Lüdenscheid & Germany ERCO: Global Networks

Supply Chain Context

A supply chain consists of all parties involved, directly or indirectly, in fulfilling a customer request. The supply chain not only includes the manufacturer and suppliers, but also transporters, warehouses, retailers, and customers themselves. Within each organization, the chain includes all functions involved in

ERCO specialises in producing engineering hardware and software for architectural lighting. ERCO’s indoor/outdoor luminaries and lighting control systems constitute a large range of lighting equiptment. 10 DAYS

Distribution Center -warehousing/distribution or handled by local or third party -delivery lead times in weeks, not days Sustainable Supply Chain 2%

efficiency gain






Distributors -500-1000 -non exclusive distributors -distribute product to store, credit with stores

efficiency gain

-electrical contractors -general contractors -developers 50%


Clean and modernize power at manufacturing plants

• Customers • Retailers • Wholesalers/Distributors • Manufacturers • Component/Raw material suppliers

Utilize waste heat in the production process

efficiency gain

Customer/ End User -little visibility of end customers apart from key accounts -demand and service performance masked 45%

The Supertruck, trucks with 50% more fuel efficiency

efficiency gain

Weatherize and Upkeep commercial buildings


ERCO Facade & Lighting Systems System Interface

ERCO Systems

Switch , Circuit Relay contact Neutral Conductor DALI Line

Luminaire 1 Transformer, ECG Dimmer,Acuator

Dali Controller

Other Luminaries

DALI Systems DALI Control


Digital Addressable Lighting Control (DALI) is a lighting control system which has a single interface that can control lighting devices and lighting controllers.

Light Server

Every DALI system consists of a DALI power supply and a twin 1.5mm cable referred to as the DALI line which connects the DALI devices. The DALI line can connect up to 64 devices by cabling in a star or daisy chain arrangement.

Light Changer

-Distributed intelligence for flexible control -Control of individual lights, groups and DALI Lines -Easy configuration for changing circumstances -Inerface with building management systems -Logarithmic dimming behaviour matching the eye -Increased energy savings

Dali Ballast Dali Gateway/ Controller Flourescent Lamp Ethernet Network

5 Core Internet Cabling Switch Plate

Dali Power Supply Exit Emergency


Warehousing Systems VLM The VLM is a computer controlled automated vertical lift module, storage and retrieval system. Functionally, stock within the VLM remains stationary on front and rear tray locations. On request a movable extractor unit travels vertically between the two columns of trays and pulls the requested tray from its location and brings it to an access point. Automated Storage Retrieval Systems (AS/RS) Automated controls which place the pallets through conveyors. These six machines in ERCO are controlled through software. AS/RS systems can be built much higher than in conventional warehouses. This saves floor space and labor. These systems provide instant access to a large amount of information, which the warehouse managers can track. Conveyors Conveyors use one motor for lengths of up to 100 feet, and require no electric controls to accomplish this. These are used to move good into the pre storage area. System throughput

# of S/R machines =

S/R machine capacity in cycles per hour

Storage Racks


Storage Space

Aisle Unit

Pallets Rack Width Pallets are used to hold groups of products. Plastic pallets are growing in popularity. As the become more automation friendly, they are easier to move on conveyors. Though more expensive to purchase then wooden Rack Height pallets, when used in a captive system, plasic pallets hold up more effectively and cut costs in the long run.

Rack Length

AS/RS machine

Prestorage Area

Robotics Robotics play a major role in the materials handling systems. Robotics by Fuji Yusoki, a loarge robotic palletizer manufacturer. These robotics are also used to depalletize and repallatize layers on its new storage/retrieval system.

RFID RFID can be implemented at the pallet level, case level, or unit level. The medium to long term trend is to have RFID tags at the unit level, so every time a consumer purchases can be tracked. This is still fairly costly, but most industry experts encourage unit-level RFID tagging, and predict the industry will grow. RFID readers can be easily integrated into any AS/RS to identify pallets and the product on a pallet. This data can be used later as the product moves through the rest of the supply chain.

Rack Organization System


























Automated Statistics Labor Saving (% Personnel)

Space Saving (% Area)

Automated Retrieve (% Accuracy)

67 85 99.9 max. lifting speed 3 m/s (9.8 ft/s) max. travel speed 6 m/s (19.7 ft/s)

max. payload 100 kg (220 lbs)

max. lifting acceleration 3 m/s² (9.8 ft/s²) max. travel acceleration 3 m/s² (9.8 ft/s²)

max. height 18 m (59.1 ft)


Product Flow System 3

4 2


Conveyor System to Production P1

Primary Circulation

1 ERCO Ludenscheid Products Drop off & Withdrawals

Palleter and 2 Automatic Floor Prestorage Area

Employee Control Space

3 6 Storage/Retrieval Machines

Warehouse Typologies


Structural Storage Systems Small Scale Drop Off

ERCO Product Flow Statistics 1,050

employees worldwide

big box space | Architecture?

? for person

for object

storage building as product


distribution networks


annual sales in 2010

Storage Retrieval Machines

Warehouse Size (M2)

Storage/Retrievals Per Hr

Storage Capacity

3,365 6 I80 7,000

1c URRIFRQVWUXFWLRQ PPSRO\H¿QVHDOLQJOD\HU 80-120 mm mineral wool thermal insulation to 5% falls on vapor retarding layer. Ribbed metal sheeting (80/307 mm) on steel I-beams 120 mm deep

86HFWLRQ 3 mm sheet aluminum bent to shape 30 mm waterproof thermal insulation


ÀRRUFRQVWUXFWLRQ 30 mm base board with protective coating 120 mm thermal insulation 250 mm reinforced concrete slab 50 mm galvanized steel ribbed sheeting

86HFWLRQ 262/60/7 mm and 262/41/6 mm Usection vertical glass elements galvanized steel I-column 120 mm deep

PDLQWHQDQFHFDWZDON 100/50 mm steel RHS frame 30 mm metal grating


2c URRIOLJKW 16 mm polycarbonate double-web cellular slabs

GRXEOHJOD]LQJ laminated safety glass (2x6mm) - 16 mm cavity 10 mm toughened glass vertical joints sealed with silicone horizontal joints with aluminium cover strips 150/60 mm aluminium RHS post-and-rail facade steel I-column 400 mm deep


GRRU 3 mm sheet steel on both faces with 54 mm thermal insulation

80-120 mm mineral wool thermal insulation to 5% falls on vapor retarding layer.

Ribbed metal sheeting (80/307 mm)

Steel I-beams 120 mm deep




Here pallets form the high-bay warehouse are accessed completely automatically. Partial quantities are manually removed from pallets and put into boxes to be automatically transported to assembly


Ttechnical center rooms. This level is also constructed of solid, steel-reinforced concrete and SRO\VW\UHQHÂżOPIDLUIDFHGEULFNZRUN



The boxes are transported over the connecting bridgeon the front building of the new pallet warehouse. The steel construction is continued here.


Trucks deliver to this level and are unloaded with fork lifts.

LQWHULRUVWUXFWXUH high-bay warehouse structure is also the structure for the building

YHUWLFDOJODVVHOHPHQWV steel I-section 120 mm deep with protective coating


Facade Lighting concept developed in cooperation with Uwe Belzner. The long sides have been equipped with 140 vertical neon tubes that can be used to create nearly 250 different lighting scenarios. Their design is based on the barcodes, the basic control element of the high rack warehouse’s management.

Nighttime Activation

Panels & Catwalks: The long facades are designed as a double-skin glass profile.

Nighttime Visibility

Panel Unit: In the principle of a structural glazing construction, the U-profile opens outward.

North Corner of P3



Roof Construction: The panels of the ridged roof are made of transparent sheet glass with large panes of insulating glass. The 60 m long light bands are made of 2.20 m x 4.50 m large panels are held on two sides with clamping profiles, where the vertical glass edges are simply treated with silicon, achieving transparency through the depth of the building into the

Egress built into ERCO P3 Logo

Glazed Facades: The short facades of the P3 building, on the South-West and NorthEast faces, respectively, are made of transparent insulated glass, which allows views into the depth of the hall. Visitors to the ERCO premises get an idea about what’s going on inside in terms of automated logistics even when they’re still outside.

P3 in Landscape

Site & Slope: The building is cut into a hillside with an incline of around 16 percent, and separated from the landscape by a terraced gully. The building measurements are as follows: Width x length x height ca. 29.60 m x 73.60 m x 13.00 m (west facade) - 23.00 m (east facade)



External Structure As the design was primarily that of a new enclosure with a steel facade and roof, largely covered with transparent or translucent glass surfaces, much of the load bearing is performed by the interior, leaving the exterior as transparent as possible, and with lateral bracing devices to protect glass and resisting wind loads.

Massing Development:

Window Crossbracing looking at P1

Internal Structure: The warehouse storage and retrieval unit is fully automatic. The high-bay facility is constructed from steel. The floor plate is made in solid, steelreinforced concrete and in part is mounted on poles. Designed as a highybay, silo-shaped warehouse, the pallet racks themselves were to form the supporting structure for the new building.

Loading Dock + Conveyor Tunnel

ERCO, Lüdenscheid  

Third Year Case Study Presentation - Completed in Collaboration with Francis McCloskey

ERCO, Lüdenscheid  

Third Year Case Study Presentation - Completed in Collaboration with Francis McCloskey