Our client, the largest supplier of power and hand-tools in Ireland, recently transformed their distribution operations. Operating from a newly consolidated 50,000 square foot master facility, this strategic shift aimed to optimise space, enhance operational efficiency, and ensure the security of high-value products – as well as futureproof the business.
The Challenges:
- Space Utilisation: The new facility needed to accommodate vast inventory without compromising storage efficiency, and freeing up additional bulk storage capacity.
- Efficiency: Improving the speed and accuracy of order fulfilment was essential, as manual processes, over a large footprint previously hindered these aspects.
- Security: High-value items required enhanced protection against theft, loss, or damage.
Hänel Lean-Lifts in operation at a leading Distribution Centre – a video interview with the Operational Manager, Ian Walker.
To address these challenges, the client turned to Industore, recognising them as the leading supplier of AS/RS (automated storage and retrieval systems) in Ireland. Industore’s advanced vertical lift modules (VLMs), “Lean-Lifts”, were chosen for their innovative features and proven effectiveness, as Operational Manger Ian Walker explains:
“Industore were our preferred choice for several reasons. They were clearly the leaders in intralogistics, and their calculations and understanding of the work required to meet our needs were far and away the best. They demonstrated that they could replace a three-tier mezzanine system covering around 150 square meters [about half the area of a tennis court] with three Lean-Lifts occupying under 50, without considering all the additional benefits the lifts would bring. They helped us visualise exactly what this would look like, and how it would work for us, showcasing similar solutions at other sites. Their references really spoke for themselves, all the reports we had were absolutely glowing.”
Transitioning from mezzanines to Lean-Lifts freed up significant floor space, allowing the client to increase their range of tools and equipment. The Lean-Lifts greatly enhanced the speed and precision of product retrieval. Industore’s “pick-to-light” system reduces typical errors associated with picking similar-looking parts, ensuring high accuracy in order fulfilment. On this site, many parts are very similar in appearance to another, and to the naked eye, items such as spanners may only have a centimeter of difference to them. Our client also have several items stored in identical packaging, with only a single part number differentiating one item from the other. On shelves, particularly if these shelves aren’t very well organised and tidied frequently, these could so easily be mistaken and mispicked. Moreover, the secure design of the Lean-Lifts has added a layer of protection for what are very high-value products. Fob and PIN options restrict access, and full audit controls allow managers to review access history at the click of a button. For clients storing particularly sensitive inventory, camera integration options are available to document picks visually.
Ian Walker again:
“We’d visited a number of other Industore sites, and several of their clients included some of our leading partners and suppliers, which added confidence to Industore’s solution and their credibility. Perhaps the most important factor leading to Industore as our chosen partner in this venture was their service provision. They were more responsive than other providers, and able to fulfil the order more quickly. They also had a very strong base in Ireland, with added reassurance that in the unlikely event that something went wrong, they’d be able to react quickly – which, when you’re storing millions of Euros worth of inventory in their lifts, is paramount. Now, with the lifts up and running, we know we made the right decision with Industore. The service has been exceptional – absolutely faultless, in fact.”
The Lean-Lifts’ automatic height sensors will continue to accommodate changes in stock and products as our inventory rotates, optimising storage based on a number of factors, ranging from item size, frequency of use, and common picks (items which are picked frequently together, but stored on different shelves, for example). Of course, company preference is also considered, and ultimately, the intuitive tools and intelligence within the lift can be overwritten, should there be a particular policy or procedure that needed to be adhered to. On top of all this, intelligent reporting will empower better decision-making and is already improving retrieval times. As the company expands, additional lifts can be seamlessly integrated, without interruption, even if they’re specified differently – shorter, wider, narrower, with multiple access points, or just about anything else.
As with all projects, Industore prioritised safety and ergonomics during this installation. Advanced safety features, such as multiple sensors and light barriers will prevent accidental interference or injury. The ergonomic design allows for consistent, ‘one-location’ item dispensing, reducing the physical strain on workers and enhancing overall safety. The automated system has also drastically reduced manual handling and walking distances within the facility, further increasing productivity.
Despite significant workflow changes, the workforce has adapted well to the new system, thanks to extensive user training provided by Industore staff. Ian Walker concludes:
“Trevor, our project manager, has been incredibly supportive and knowledgeable. His passion for the Lean-Lift product and commitment to our success was evident throughout the process. Moving and centralising our facility was a big cultural change for our staff, and we emphasised that there would be no redundancies due to this investment, because we were aware that such news can be disconcerting. However, since the implementation, our warehouse staff are now much happier using the Lean-Lifts than working in the racking and open warehouse areas. They’re able to complete their work more quickly, safely, and without the physical strain of navigating a large warehouse, or covering great distances.”
Industore’s Lean-Lifts have proven invaluable for our client, addressing critical operational challenges and laying the foundation for future growth. The combination of space optimisation, improved speed and accuracy, and enhanced security has enabled the client to modernise their distribution operations and achieve significant efficiency gains. The support and expertise provided by Industore, particularly through their project management team, has been listed time and again as being instrumental in the successful implementation of these Lean-Lifts – and the wider success enjoyed by this new site. We look forward to a positive future with this client, and to specifying what will be a fourth lift in the coming year.
