Discover how PCS Company, a leading supplier to North American mold makers, revolutionized its logistics operations, increasing capacity and accuracy, thanks to the implementation of Modula’s vertical lift modules (VLMs)
The Challenge
PCS Company faced significant challenges related to growth and the physical limitations of its warehouse:- Limited space: The company was running out of space, which was an obstacle to future growth and could have required a move.
- Inefficient storage systems: Managing approximately 12,000 parts with traditional shelving required wide aisles, limiting storage capacity.
- Expansion plans at risk: The company anticipated substantial growth in the next 4-5 years but lacked the physical space to handle increased capacity.
- Operator safety: Traditional methods posed risks, such as the need for operators to climb ladders to reach items stored up high.
- Picking errors: Errors in order picking could jeopardize customer relationships and trust.
The Solution
To address these challenges, PCS Company chose to invest in Modula’s vertical lift modules. The decision was made after carefully evaluating the solutions:- A team from PCS Company visited Modula’s headquarters in Dayton, where they saw both horizontal carousels and vertical lift modules in action and were very impressed with the technology
- The implementation proved to be very simple. Operator training took only a few hours, as the system was found to be very intuitive and easy to use.
- The main challenge was integrating the computer systems, rather than training the staff, which attests to the user-friendliness of the VLMs.
Why Modula?
PCS Company’s choice of Modula was based on specific strategic reasons:- Impressive efficiency and technology: The visit to Modula’s headquarters convinced the team of the solution’s value.
- Safety and ergonomics: The VLMs eliminate the need for operators to climb ladders, reducing the risk of injuries. They also improve ergonomics, as operators no longer have to bend over or push carts down aisles.
- Ease of use: The system is very intuitive and easy to learn, which made training quick and effective.
- Picking accuracy: Reducing picking errors was a critical factor for the investment to maintain high customer confidence.
The Results
The adoption of Modula VLMs led to significant and quantifiable improvements:- Space optimization: By utilizing vertical space, PCS Company was able to store about 40% of its parts (5,000 out of 12,000) in the VLMs, freeing up valuable floor space and enabling future growth within the same facility
- Square footage is the most valuable asset in a warehouse, and Modula maximizes its use.
- Increased efficiency and capacity: The company increased its picking capacity from about 1,500 lines per day to over 2,000, gaining the flexibility needed to support growth.
- Improved inventory management and accuracy: Picking accuracy increased by about 40%, and returns (RMAs) dropped to single digits. This error-proofing system boosts operator confidence in their work.
- Enhanced safety and employee satisfaction: Eliminating the risks associated with using ladders and improving ergonomics has been a huge benefit for employee safety. Employees are proud to show off the new system, demonstrating that it has been very well-received.