Heavy Machinery Irregular Components
Custom Non-Standard Warehousing Project
Key Results
Quality Control Breakthrough: Irregular Component Damage Rate Slashed to 1.3%
Capacity Expansion: Storage Capacity Increased by 48%
Throughput Optimization: Inbound & Outbound Efficiency Improved by 52%
Project Pain Points
The structural components storage area spans 1,800㎡, housing multiple categories of heavy machinery parts including hydraulic pipeline assemblies, irregular machine frames, and non-standard pin shafts. Due to the highly non-standard nature of these part specifications, generic racking systems could not support the highly diverse geometric dimensions. Furthermore, manual rigging and crane-hoisted handling resulted in high bumping and scratch-induced damage rates, while the sheer complexity of the part categories made classification difficult, leading to disorganized and chaotic inventory ledgers.
Core Solutions
■Specialized Material Handling: Deployed custom stacker cranes equipped with widened forks alongside heavy-duty, load-shifting non-standard AGVs.
■Modular Flexible Racking: Co-developed modular, adjustable racking structures to dynamically adapt to shifting component shapes and dimensions.
■Zoned Hardware Sorting: Allocated dedicated zones for small standard parts and valves utilizing high-visibility Pick-to-Light (PTL) racking.
■Unique Serial Tracking: Instituted a strict "One Item, One Code" digital control framework across all component categories to ensure continuous traceability.
Business Value Delivered
■Drastic Drop in Defect Losses: Slashed the storage damage rate of irregular components from 9% down to 1.3%. Standardizing automated storage and retrieval eradicated scratching and collision hazards from the root, noticeably shrinking material scrapping overheads.
■Dual Gains in Capacity & Speed: Expanded non-standard inventory storage capacity by 48% and lifted overall outbound/inbound efficiency by 52%, seamlessly supporting high-mix, low-volume manufacturing kitting rhythms.
■Total Management Efficiency: Enabled end-to-end digital tracking across all product lines with real-time stock synchronization, thoroughly resolving the legacy administrative bottleneck of cataloging irregular parts and executing tedious inventory counts.
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