Komatsu is a global leader in mining and industrial equipment, operating over 100 plants worldwide with more than 64,000 employees.The UK-based Komatsu facility in Manchester plays a pivotal role in supplying hydraulic components to global sister plants while also supporting UK mining operations with service centre capabilities. As the business continued its expansion, storage space was becoming more constrained. Ultimately, Komatsu required a higher-density, more space-efficient storage system for high-value, high-volume parts while streamlining warehouse operation.
Solely traditional racking systems were no longer viable for Komatsu’s needs, particularly with warehouse space shrinking. The company required a compact, automated storage solution (AS/RS) to enhance efficiency. Following a thorough go to market exercise, Industore were selected as the preferred supplier, and the Rotomat, our automated storage carousel, the preferred solution.
WATCH NOW: Industore’s Rotomat video case study, at Komatsu.
Industore recommended and specified a Hänel Rotomat – and Komatsu quickly recognised that this solution was outperforming competitors in terms of build quality and efficiency, and Industore, in terms of turnaround time and reliability.
The Rotomat has enabled Komatsu to:
Storing over 2,160 bins in the space of just three pallets, reclaiming over 100m² for enhanced operational use.
Secure, traceable storage ensures that high-value components remain uncontaminated and accounted for, always.
Eliminates manual searching, drastically reducing pick times or erroneous picking.
Trademarked EcoMode® and EcoLoad® technology lowers energy consumption by optimising load distribution and power usage.
Andy Atherton, Operations and Facility Manager at Komatsu on ‘Why Industore’:
“We always buy ‘the best’. That’s the ethos Komatsu and the wider Joy Group have always operated on – not just the best solution, but the best business partner. Before the go-to-market exercise concluded, it was clear that the Rotomat was the best-in-class automated solution for our needs, and Industore the best partner. The build-quality, the ease of use, and the aftercare support all stood out.
Industore took the time to truly understand our needs and specify the right product for us. The process, transparency, and client references were excellent. Industore even arranged visits to similar, nearby sites to see the system in action, and get feedback from Industore clients. Industore weren’t the cheapest, but they were the best – and ultimately, that’s what we’re about.”
Increased Throughput, Security, and Compliance:
The Hänel Rotomat has significantly enhanced Komatsu’s warehouse efficiency, providing numerous advantages:
The Rotomat frees up warehouse space, allowing Komatsu to focus on operations and expansion.
Operators retrieve multiple items in seconds, eliminating inefficient manual searches or picking the wrong parts.
Parts are enclosed and access, tracked, ensuring complete inventory control.
Items are always picked at an ergonomic height, reducing strain and workplace injuries – a significant consideration of Komatsu’s.
EcoMode® powers down the system when idle, while EcoLoad® ensures balanced weight distribution, further lowering energy usage.
Komatsu’s Rotomat has been in operation for 18-months with zero downtime or performance issues. This success has led the company to consider additional Hänel solutions, including the Lean-Lift, Hanel’s Vertical Lift Module (VLM) to further optimise storage.
Andy Atherton again:
“There’s roughly £5 million worth of parts in our Rotomat, but if a replacement part is delayed, the cost of our downtime would quickly out-pace the value of the parts themselves. We wouldn’t store our critical inventory anywhere without absolute confidence in its reliability, and ultimately, we have that confidence in the Rotomat, and in Industore.
Industore’s UK-based service team is incredibly well-equipped, knowledgeable, and strategically placed. We have an Industore service contract in place, and we’ve met with local engineers – which again, added confidence. Knowing that Industore’s head offices are located in Cardiff and Dublin also gives additional peace of mind. It’s knowing that if anything does go wrong, the locals will be here quickly, and worst-case-scenario, replacement parts are just a few hours away. Our relationship with Industore, despite only being two years old, is an extremely strong one, built on trust and mutual respect. I couldn’t recommend them enough.”
Komatsu’s investment in Industore’s automated storage system (AS/RS) has delivered exceptional ROI, improving efficiency, safety, and storage capacity without expanding warehouse space. The Rotomat has become integral to daily operations, ensuring smooth inventory management and supporting Komatsu’s 24-hour call-out function for its UK mining clients.
Steve Anderson-Tyso, Industore’s Project Manager for Komatsu, concludes:
“Komatsu is a natural partner for Industore. Their commitment to best-in-class solutions aligns with our own dedication to delivering the world’s leading automated storage and retrieval systems [AS/RS]. We’re extremely pleased to be working with another company at the absolute cutting edge, and top of their game. To see another Industore client achieving more with less is something I’ll never get old of. It’s absolutely the Industore way.”
