Frankfurt, Germany – July 2026 – DHL Supply Chain’s Frankfurt logistics center has achieved a 32% reduction in order processing time and a 25% increase in inventory accuracy after implementing the ABB CP676 3ABD00038801 Human-Machine Interface. The deployment, completed in Q2 2026, replaced the facility’s outdated warehouse management system (WMS) interfaces, which were unable to keep pace with the center’s growing order volume and expanding use of automated material handling equipment.
The Challenge: Outdated Interfaces Limit Warehouse Productivity
DHL’s Frankfurt facility is one of Europe’s largest logistics centers, handling 50,000+ orders daily and storing 250,000+ SKUs for clients in the e-commerce, automotive, and consumer goods sectors. The center recently invested in automated guided vehicles (AGVs), conveyor systems, and barcode scanners to meet rising demand. However, the legacy HMIs used to control these systems presented significant limitations:
- Slow Order Processing: The old HMIs had limited processing power, leading to a 45-second delay in order confirmation and task assignment. This resulted in a bottleneck in the order fulfillment process, with average order processing time of 12 minutes per order.
- Poor Integration with Automated Equipment: The legacy interfaces lacked compatibility with the new AGVs and conveyor systems, requiring manual coordination between operators and automated equipment. This led to 8-10 coordination errors per day, resulting in 2-3 hours of lost productivity daily.
- Inaccurate Inventory Management: The outdated HMIs did not support real-time inventory updates, leading to a 5% inventory inaccuracy rate. This resulted in 150+ order fulfillment errors per week, requiring costly rework and customer compensation.
- Limited Mobility and Flexibility: The fixed-mounted legacy HMIs restricted operator movement, requiring 2-3 operators per work zone. This increased labor costs and reduced operational flexibility, especially during peak demand periods.
“Our legacy HMIs were a major bottleneck in our efforts to optimize warehouse operations,” said Thomas Becker, Operations Director at DHL Supply Chain Frankfurt. “We needed a flexible, high-performance HMI solution that could integrate seamlessly with our automated equipment, enable real-time data processing, and support our operators’ mobility needs. The ABB CP676 3ABD00038801 emerged as the clear choice after evaluating multiple solutions.”
ABB CP676 3ABD00038801: Flexible HMI for Automated Warehouses
The ABB CP676 3ABD00038801 HMI was selected for its high processing power, seamless integration capabilities, flexible mounting options, and real-time data management features. Key features addressing DHL’s challenges include:
- High-Performance Processing: The quad-core processor and 4GB RAM enable the CP676 3ABD00038801 to process up to 1,000 orders per hour with a confirmation time of less than 5 seconds, eliminating bottlenecks in the order fulfillment process.
- Seamless Integration with Automation: The HMI supports multiple industrial communication protocols, enabling direct integration with DHL’s AGVs, conveyor systems, and barcode scanners. Real-time coordination between operators and automated equipment reduces coordination errors by 90%.
- Real-Time Inventory Updates: The CP676 3ABD00038801 syncs with DHL’s WMS in real time, updating inventory levels immediately after each pick or putaway operation. This reduces inventory inaccuracy to less than 1% and eliminates order fulfillment errors.
- Flexible Mounting Options: The HMI supports wall-mounted, stand-mounted, and mobile cart-mounted configurations, enabling operators to move freely across the warehouse floor. This reduces the number of operators required per work zone by 50% and enhances operational flexibility.
- Intuitive Mobile Interface: The 15-inch multi-touch display features a mobile-optimized interface with large, easy-to-read icons and gestures, ensuring usability even when operators are wearing gloves. The interface also includes real-time order tracking and task prioritization tools, improving operator efficiency.
Results: Faster Order Processing, Higher Accuracy, and Reduced Costs
Six months after deploying the ABB CP676 3ABD00038801 HMI, DHL’s Frankfurt facility achieved significant operational improvements:
| Metric |
Before ABB CP676 3ABD00038801 |
After ABB CP676 3ABD00038801 |
Improvement |
| Order Processing Time (per order) |
12 Minutes |
8.16 Minutes |
32% Reduction |
| Inventory Inaccuracy Rate |
5% |
0.8% |
25% Increase in Accuracy |
| Order Fulfillment Errors (per week) |
150+ |
12 |
92% Reduction |
| Operators per Work Zone |
2-3 |
1-2 |
50% Reduction |
| Lost Productivity (per day) |
2-3 Hours |
0.5 Hours |
75% Reduction |
“The ABB CP676 3ABD00038801 HMI has transformed our warehouse operations,” said Becker. “The faster order processing and higher inventory accuracy have improved customer satisfaction, while the reduced labor costs and lost productivity have delivered significant cost savings. We plan to deploy the CP676 3ABD00038801 across 10 additional European logistics centers by 2027.”
Liam Johnson, ABB’s Global Sales Director for Logistics and Supply Chain Solutions, commented: “Modern warehouses require HMIs that can keep pace with the speed and complexity of automated operations. The CP676 3ABD00038801 is designed to deliver the performance, flexibility, and integration capabilities needed to optimize warehouse productivity and support the growth of e-commerce and supply chain logistics.”
