Minimal downtime, maximum planning reliability: At Strautmann Hydraulik GmbH & Co. KG, an existing bar stock warehouse supplied by a third-party provider was comprehensively modernized in just nine working days. A key factor in the project’s success was meticulous preparation combined with a clear focus on system availability rather than maximum performance. To carry out the retrofit, Strautmann placed its trust in Fehr.
Project overview
- Location: Melle (Germany), long-stock warehouse serving as the central material supply source for production
- 30,000 m² of production space
- 817 storage spaces in a building-supporting structure
- Retrofit of an existing long-item warehouse from a third-party provider (built in 2012) to increase availability and ensure future-proofing
- Complete replacement of the stacker crane, including updated aisle equipment, safety devices, and replacement of the electrical control system
- Implementation of the fehr WMS, including adaptation to existing processes and additional functionalities
- Completion in just 9 business days while production continues; modernization from January 28 to February 11, 2026; handover on February 13, 2026
The bar stock warehouse at Strautmann Hydraulik’s facility in Melle, Germany, is a key component of the company’s material supply chain. Across more than 30,000 m² of production space, Strautmann Hydraulik manufactures hydraulic cylinders for a wide range of industries, including mechanical engineering, commercial vehicles, and wind energy. As a result, the company relies on a highly dependable and continuous supply of raw materials to maintain efficient production operations.
The bar stock warehouse is at the heart of our production operations. That made it essential for us to take action early and in a controlled, well-planned manner.
Bastian Wasmus, Head of Materials Management, Strautmann Hydraulik GmbH & Co. KG
Modernization Instead of Risking Downtime
Although the existing third-party system, installed in 2012, was still relatively young from a technical perspective, limited spare parts availability and quality-related shortcomings made a proactive replacement investment necessary. As Bastian Wasmus, Head of Materials Management at Strautmann, explains: The bar stock warehouse is at the heart of our production operations. That made it essential for us to take action early and in a controlled, well-planned manner.
Fehr Selected as a Low-Risk Retrofit Partner
One of the key criteria in selecting an implementation partner was the ability to understand and further develop an existing system architecture—regardless of the original manufacturer. Following reference visits and detailed discussions, Strautmann Hydraulik chose Fehr. Decisive factors included Fehr’s extensive experience in retrofitting third-party systems and its ability to deliver the mechanical components, control technology, and warehouse management system as an integrated, low-risk solution.
Handling performance is not the key metric for us. What matters is reliable, trouble-free operation and a dependable supply of materials to production.
Bastian Wasmus, Head of Materials Management, Strautmann Hydraulik GmbH & Co. KG
Clear Requirements for the Retrofit
The objective was to modernize the system with minimal disruption to production while continuing to utilize the existing infrastructure. This included 817 storage locations within a rack-supported building structure, as well as various cassette types with payload capacities of up to 4,000 kilograms.
A key requirement was the seamless integration of the new automated storage and retrieval system (ASRS) into the existing storage aisle. At the same time, the existing inbound and outbound stations, as well as the current load carriers, were to remain in operation without modification.
The site conditions also presented significant challenges. The warehouse is directly adjacent to an active CNC production area, considerably limiting the logistical options available during the retrofit.
Flexibility was equally important on the software side. The new warehouse management system (fehr WMS) had to adapt to established workflows while also providing additional functionality to support future operational requirements.
The automated storage and retrieval system (ASRS) was completely replaced and seamlessly integrated into the existing storage aisle, including upgraded aisle equipment.
Precise Planning as the Key to Success
Fehr began by conducting a detailed analysis of the existing installation and developing a precise retrofit strategy. This included assessing the mechanical components and safety systems, designing a new safety concept, and upgrading the control technology.
A critical aspect of the planning process was safeguarding production during the retrofit. To achieve this, Strautmann deliberately created operational buffers. By increasing pre-production in the cutting department and establishing additional interim storage capacity, the company was able to temporarily secure its material supply. At the same time, approximately 60 cassettes were removed from the system to create sufficient space for the installation work.
Ultimately, the retrofit was completed in less time than originally scheduled.
Bastian Wasmus, Head of Materials Management, Strautmann Hydraulik GmbH & Co. KG
Modernization in Just Nine Working Days
The modernization took place between January 28 and February 11, 2026. Within this period, the existing ASRS was completely replaced, the electrical control system renewed, and the new warehouse management system (fehr WMS) implemented. Operational production was interrupted for only nine working days; the official handover took place on February 13.
“The actual retrofit phase was even shorter than originally planned,” reports Wasmus. “What stands out in particular is the professionalism of the on-site installation team, which made full use of the available time and completed the retrofit as quickly as possible.”
Focus on Availability and System Stability
Technically, the modernized system fully replaces the previous installation. In addition to the new SRM, the scope of delivery also includes upgraded aisle equipment, safety systems, and the new fehr WMS.
During early operation, the system already demonstrates a clear advantage: high stability combined with improved dynamics. However, for Strautmann, maximum throughput is not the primary objective—system availability is.
“Handling performance is not the key metric for us. What matters is reliable, trouble-free operation and a dependable supply of materials to production,” says Wasmus. “We are very satisfied after the first weeks in live operation—the system has been running stably from day one.”
The electrical control system was upgraded to ensure future readiness and long-term system reliability.
Retrofit as a Strategic Option
The project at Strautmann Hydraulik exemplifies the potential of modernizing existing intralogistics systems. By selectively upgrading key components, system availability and future readiness can be significantly improved—without the investment costs and risks associated with a complete new build.
In production-critical environments, where downtime results in high costs, a carefully planned retrofit offers a compelling economic and technical alternative. However, this requires a holistic approach that considers mechanics, control systems, and software alike, as well as an execution strategy consistently focused on minimizing operational disruption.
About Strautmann Hydraulik GmbH
Based in Melle (Germany), Strautmann Hydraulik specializes in the development and production of hydraulic cylinders and control blocks for mechanical and plant engineering applications. The company is part of the internationally operating Strautmann Group and supplies customers across Germany and Europe. Its portfolio includes both standard solutions and customized special cylinders designed for applications with high demands in terms of force, precision, and reliability. Production is carried out using state-of-the-art manufacturing systems with a high degree of automation.
