Johnson Matthey PLC is a multinational, speciality chemicals and sustainable technologies company, listed on the London Stock Exchange.
At their Hydrogen Fuel Cell Technology Centre in Swindon, the organisation needed to improve their storage provision, as demand for space was outstripping capacity; using only traditional racking and shelving. To address this challenge, Johnson Matthey partnered with Industore Limited to specify a bespoke Lean-Lift, a leading automated storage and retrieval unit (sometimes referred to as a Vertical Lift Module, or ‘VLM).
Richard Piper, the Mechanical Design Lead at Johnson Matthey:
“As the company has grown and expanded, new activities have taken up gradually more and more of our storage space. As a result of this, our storage had become more chaotic, less secure and our inventory was becoming ever less tracible. We knew that real change was needed as our stock started to bleed into other, more public areas of the building, and so we approached the market to see what solutions were available.”
WATCH NOW: Industore’s video case study in Johnson Matthey, with Mechanical Design Lead, Richard Piper.
Industore’s thorough site-audit identified several opportunities to maximise vertical space utilisation with Lean-Lift technology, providing the scalability our client sought. The audit also revealed Johnson Matthey had little control over their inventory, as it was not integrated into their warehouse management system (WMS). Project Manager, Steve Anderson-Tyso determined that a single Lean-Lift would be adequate to meet both existing demand and allow some additional capacity for future need. Today, the lift reaches the full available height of the facility, stopping short of the services, suspended from the ceiling. The Lean-Lift provides a number of key benefits:
Space Optimisation: The new, bespoke lift measures more than 5m high, utilising the full height of the facility. This allows Johnson Matthey to store all their excess inventory in around 9m2, which is more than five times the efficiency of their previous storage arrangement.
Accuracy, ergonomics and pick-speed: As with all Industore machines, Johnson Matthey’s Lean-Lift was designed to meet our client’s exact needs, while keeping ergonomics, accuracy and speed in mind. Pick-to-light technology will ensure that picking errors are all but eliminated, while waist-height, goods to person (previously ‘G2M’) delivery will ensure no straining or stretching while picking or replenishing items.
Warehouse Management Integration: The new system comes complete with Industore’s proprietary WMS system, HänelSoft – empowering Johnson Matthey to keep 100% traceability on their stock, as well as ensure they know who took what, when and why – bolstering security and improving purchasing decisions.
Lift Customisation: The Lean-Lift has been finished in Johnson Matthey’s brand blue and adorned with the company logo – taking pride of place, at the centre top of the lift. The customisation was achieved through collaboration between Johnson Matthey and Industore’s marketing team, as Shauna Aquilina explains:
“We understand the power of branding, which is why we offer clients customisation options, such as machine colours and logos. Whether visible to customers or simply internal staff, branding can enhance company identity and foster alignment with corporate values. The ‘Johnson Matthey blue’ made our lift a truly striking introduction to our client’s warehouse. Seeing the finished article, and how well it resonated well with their staff (as well as enhanced the facility’s aesthetic appeal) was great to see.”
Installation and Implementation
Installation of the Lean-Lift at Johnson Matthey was a smooth and efficient process, completed in just three-days. Richard Piper, again:
“The whole Industore team have been fantastic throughout. They were incredibly responsive when we first approached them, took the time to get to know our challenges and ambitions, and supported us throughout the design, delivery and training stages. I can’t praise the installation team enough. This space is a challenging one. There’s just a few square feet to work in – but it didn’t rattle them at all. We allocated five-days to complete the install, but they completed it in just three. Their I.T. team integrated HänelSoft to our existing stock taking system in record time. Really, I was shocked at how quickly and efficiently the entire process was concluded.”
Industore’s tried and tested, phased installation process was concluded with zero disruption to Johnson Matthey’s operations, and the intuitive nature of the machines has ensured that staff quickly got used to the Lean-Lift and its operation.
Immediate Benefits and Positive Impact
At the time of writing, Johnson Matthey’s Lean-Lift had been operational for just three-weeks. Despite this, the lift had already demonstrated its effectiveness. By consolidating various storage areas into a single, vertical solution, Johnson Matthey freed up significant ‘new’ activity space, which has already been repurposed, for new and critical functions, including new charging equipment and additional assembly areas.
The Lean-Lift’s advanced inventory management capabilities is already providing Johnson Matthey with accurate, real-time data on stock levels, locations, and movements – which is informing future decision making. The improvement is streamlining stock taking in a tangible way, in that it is always now providing accurate, real-time information on inventory and its movement – ensuring greater compliance with rigorous industry standards.
Enhanced Security and Safety
Security and safety were paramount considerations for Johnson Matthey. The Lean-Lift addressed these concerns with built-in security features, such as access code management (via PIN and/or user ID card), ensuring only authorised personnel can access the stored items. Further restrictions have also been placed on individual shelves, ensuring only authorised personnel can access goods of a more sensitive nature. Additional security features include shelf image capture, so that in the unlikely event of pilferage, images can be quickly pulled from the WMS, documenting who took what, when and from where. The system’s light guards and fail-safe sensors provide additional layers of protection, enhancing health and safety by stopping the machine if any careless access was attempted. Perhaps most importantly, Johnson Matthey have opted for Industore’s unique fail-safe system – ensuring that in the very unlikely event of a breakdown (for example, due to sensor failure) inventory can still be called upon, given the appropriate access rights, and proper precautions and procedures are followed. This ensures that there is no down-time, while an Industore engineer is en-route to the site.
Johnson Matthey’s experience with Industore Limited and the Lean-Lift has been overwhelmingly positive. Looking ahead, our client is already considering expanding their use of Lean-Lifts to further optimise their storage capabilities, and futureproof the organisation, without the need for expensive and disruptive site-expansion. The success of this initial installation has set a strong precedent for future collaboration between the two companies.
Conclusion
The partnership between Johnson Matthey and Industore Limited highlights the transformative impact of bespoke storage solutions in addressing complex operational challenges. By implementing the Lean-Lift, Johnson Matthey not only maximised their storage efficiency but also improved inventory management, enhanced security, and elevated the overall aesthetics and safety of their facility.
This project underscores the value of tailored, innovative solutions in driving operational excellence and supporting business growth. For Johnson Matthey, the Lean-Lift has proven to be a critical asset in their continued pursuit of technological advancement and sustainability in the hydrogen fuel cell sector.
