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Kardex and Zühlke: New control software in record time – avoiding a production stop
When the success of a product plays a pivotal role in a company’s future viability, fast decision-making, technological expertise, and a strong project team are essential. Together with Zühlke, Kardex successfully developed a new control solution for its highest-revenue product in just 18 months, laying the foundation for future innovation.
The project at a glance
Kardex is a global leader in automated storage and material handling systems. The company provides intelligent solutions for dynamic warehousing, bespoke order fulfilment, and efficient material flow management. It is among the world’s leading AutoStore partners. With over 30 locations and around 2,500 employees, Kardex is a key player in the international intralogistics market.
Vertical Lift Modules (VLMs) are among the most important and successful products in the Kardex portfolio. To ensure their continued availability and further development, it was necessary to modernise core components and the associated control software.
Together with Zühlke, Kardex initiated a future-oriented successor solution that sets new standards in both hardware and software, forming a technological basis for ongoing innovation.
A technological reboot under immense time pressure
Two years prior to engaging with Zühlke, Kardex had already initiated the development of new machine control software in collaboration with an external partner. Despite significant efforts, progress lagged, making a realignment necessary. To maintain delivery capabilities and regain momentum, Kardex decided to bring Zühlke on board as an additional strategic partner.
“Zühlke provided the project with critical momentum as a partner that not only analyses but also takes ownership and plays an active role in execution.”
In this decisive phase, the project was successfully restructured. Zühlke began with a structured project assessment. It quickly became apparent that the existing architecture was ill-suited for the specific use case. The joint project team identified resource gaps and technical bottlenecks – and recommended a complete technological reset, leveraging the architecture of a parallel Kardex development.
Agile team structure and clear roles drive progress
Together, Kardex, Zühlke, and the existing partner established a focused, agile team setup, featuring experienced Kardex personnel, architects and engineers from Zühlke, and a restructured team from the original partner.
A clear and agile roadmap, iterative and focused development, and close collaboration with business stakeholders ensured transparency, pace, and sound decision-making. In just 18 months, the new control solution TIC VLM was market-ready, providing a technological foundation for future innovations, particularly in IoT, cloud connectivity, and Software-as-a-Service (SaaS). Kardex’s delivery capability was secured for the long term.
“Together with Zühlke, we not only significantly reduced our time-to-market, but also laid the foundation for our next wave of innovation. ”
Key project outcomes at a glance:
- Time-to-market reduced by a factor of three, while maintaining quality and functionality.
- Long-term product availability ensured, securing Kardex’s position in the market.
- A scalable technological platform created, ready for future machines and product generations.
- Foundations laid for new digital business models, including subscription-based revenue and business models.
With an optimally simplified technological approach, a well-coordinated team with clearly defined responsibilities, and a focused strategic direction, even highly complex initiatives can be executed successfully in a short timeframe.
