True Transformation and Industry 4.0 with Industore
Innovative Technology, a leading manufacturer and distributor of cash-in cash-out systems, sought an efficient storage solution to optimise their warehouse operations. Having previously seen the promise of automated storage and retrieval systems (AS/RS) but experiencing poor customer service from an alternative supplier, they performed a go-to-market exercise, before naming Industore as their preferred supplier, for their ambitious industry 4.0 project.
Innovative Technology faced several challenges:
- Inefficient space utilisation
- Time-consuming retrieval processes
- Misplaced or incorrectly picked parts
WATCH: Industry 4.0 with Hänel Lean-Lifts. A video interview with Production Manager, Elizabeth Finn.
After evaluating their needs and setting a clear growth and improvement strategy, Innovative Technology opted for Industore’s Lean-Lift due to its superior features as well as Industore’s reputation in the UK and Ireland markets. Following a thorough site-audit by an Industore Project Manager, a single Lean-Lift was specified, designed to provide:
- Improved Access and Efficiency: Quicker access to components, drastically reducing retrieval time over accessing via racking or having to use ladders and forklifts.
- Integration to WMS: Industore’s Lean-Lift has been integrated with Innovative Technology’s stock-taking system, ensuring there’s always full visibility of stock levels.
- Space Utilisation: 30,000 parts are now stored in a footprint of some 7m2, compared to the previous racking arrangement, which required close to 50m2.
- Pick-to-Light Technology: On-lift indicative lighting accurately identifies parts for picking, virtually eliminating picking errors, and improving throughput rates.
- Ergonomics: Now, all parts are presented at an optimal height, eliminating bending or reaching, thereby reducing injuries.
Innovative Technology had previously partnered with another AS/RS company, but faced intermittent reliability issues, and long response and repair times. Understanding the need for good customer service, and quality machinery, the organisation drafted detailed service level agreements. Industore were confident in our technology and build-quality, as well as our trained, qualified staff. Industore machines can also be specified with a fail-safe system, allowing manual operation in the event of certain breakdowns, similar to a car’s “limp mode.”
Elizabeth Finn, Production Manager at Innovative Technology:
“If we can’t access our inventory, production stops, which can cost tens of thousands of pounds an hour – but since the Lean-Lift has been up and running, that simply hasn’t happened.
We always know what we have in the lift, where it’s stored, and we can access it quickly; thanks to the speed of the lift, and the pick-to-light. We’ve never had a breakdown, but if we did, we have the ESB [emergency safety bypass] which means we can access any part we need, even if say, one of our forklifts accidentally damages the safety curtain. We also know that Industore has such a good presence in the UK, that if there’s a catastrophic breakdown, we’ll be well looked after, and quickly.”
The installation of Innovative Technology’s Lean-Lift was meticulously planned and executed, with all parts arriving ahead of the Industore build team. Within just three-days, the lift was installed, causing zero disruption to the company’s operations. As with all Industore installations, extensive training and support was provided. Innovative Technology also has access to Industore’s online training repository for continuous, immediate training and quick refreshers, as well as access to a regional project manager, who is always on-hand for day-to-day assistance and guidance – whether by phone, or in person.
Since the installation of the Lean-Lift, Innovative Technology has seen significant improvements:
- Operational Efficiency: Retrieval times have been reduced from hours to minutes.
- Accuracy and Reliability: Pick-to-light and Industore’s renowned four-chain system has enhanced part selection and reliability.
- Support and Maintenance: Industore’s UK and Ireland-based support systems ensure quick and efficient resolution of any issues, queries or additional training.
Elizabeth Finn on Industry 4.0:
“We had other automated carousels in the past, from a different provider. They were based mainly abroad, and were unresponsive, even when something went wrong. This wasn’t just inconvenient; it was disruptive to production and order fulfilment, which was at times very costly. That’s a far cry from our experience with Industore, who are based exclusively in the UK and Ireland. Industore can’t do enough to help us, ever. We’re extremely pleased with the product and the relationship that we enjoy with them – and I, and I’m sure the entire team at Innovative Technology wouldn’t hesitate to recommend them.”
Industore’s Lean-Lift has transformed the storage and retrieval processes at Innovative Technology, delivering considerable time savings, improved accuracy, and enhanced safety. The solution has achieved the Industry 4.0 standard soughy by the client, and the partnership with Industore has proven to be a strategic move, providing Innovative Technology with a reliable and efficient storage solution tailored to their needs. The relationship between Industore and Innovative Technology continues to thrive, promising ongoing support and innovation.
