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In manufacturing facilities, there is constant pressure for more efficient operations, maximized space, and inventory accuracy. With so many moving parts and other issues including labor constraints, busy facilities are turning to automation solutions. Material handling solutions such as Vertical Lift Modules (VLMs) and Warehouse Carousels, specifically the Hanel Lean-Lift and Hanel Rotomat, bring ergonomics, accuracy, efficiency, and safety all together.

Below, we’re breaking down five key reasons why VLMs and Carousels are strategic investments you should consider in support of your manufacturing operations.

1.  Higher Productivity

Implementing a Hanel Lean-Lift or Hanel Rotomat improves workflows in manufacturing facilities. With these material handling solutions, workers call specific items or locations using a control panel and the items are delivered directly to the picker. This eliminates time searching for items or walking around the facility to gather them. This productive “goods-to-person” approach reduces travel time and keeps workers more focused on the task at hand.

Reduced Travel - Manufacturers who place VLMs near to a manufacturing line or station will find that workers appreciate the convenience of having small parts, special tools, or work-in-progress material densely-stored and readily available close-by. They don’t have to regularly stop what they’re doing and walk to a separate area to retrieve a critical item.

Up-Time - The well-known reliability and redundancies of all Hanel products are an incredibly important aspect of the productivity of workplaces where they are implemented. A VLM that is constantly down for maintenance is a great strain on a manufacturing operation. Hanel machines are inherently robust, with four-axis, chain-driven tray movement. Many of the important safety sensors critical for normal operations have built in redundancies, meaning the machine, and the customer’s manufacturing line, can continue operating when a sensor breaks and while the repair part is on order.

Ultimately, VLMs and carousels provide a powerful solution to space and inventory management that helps manufacturing facilities increase output and keep production schedules on track.

2.  Inventory Accuracy

When your storage system can communicate directly with your ERP or WMS, operations are more streamlined and automatically managed at a granular level and you can breathe easier. After implementing a Hanel Lean-Lift or Hanel Rotomat, thanks to directed picking assistance and tracking of specific bin locations as well as access control, customers typically achieve over 90% inventory accuracy.

Inventory inaccuracies are costly, so being able to manage your inventory with greater precision has a direct impact on your facility’s bottom line. These ERP-integrated automation systems allow for more accurate pick and replenishment tracking. Workers manually call down specific items to the pick window by scanning a pick sheet and are directed to the correct location on a tray or location in a carousel presentation. At a higher level of integration, the machine receives orders directly from the ERP and automatically presents location after location to a worker. Together, these features allow for a more reliable and controlled flow of inventory.

3.  Over 60% Floor Space Savings

Manufacturing facilities are packed with inventory, tools, equipment, and more. Floor space is a premium to say the least. This means high density storage is critical to ensuring the most floor space possible can be dedicated to the manufacturing process. The Hanel Lean Lift and Hanel Rotomat make this possible by allowing you to reclaim over 60% floor space savings, transforming how storage solutions can fit into your layout.

This level of floor space savings for manufacturing facilities is game changer. By freeing up such a large footprint traditionally devoted to shelving or racking, manufacturing facilities can greatly increase on-hand inventory, create additional working space for production, and maintain a more organized facility. Having more space savings can not only improve day-to-day workflow, but can really help you achieve your future goals much faster.

4.  Ergonomics

Incorporating a Vertical Lift Module or Carousel system can bring immediate ergonomic improvement to your operations. These material handling solutions eliminate the need for workers to reach overhead or down below to pick items. Instead, products are presented to them at a comfortable, ergonomic height known as the Golden Zone. This minimizes overstretching, falls from ladders, or injuries that workers might otherwise receive when picking items from traditional systems.

If you need to store heavy parts, crane solutions and roll-away trays can be integrated to take the heavy lifting off workers. These solutions, designed with the worker in mind, can allow for a safer, healthier workplace, leading to higher morale and greater job satisfaction. Overtime, a focus on ergonomics can contribute to lower turnover and a more engaged workforce.

5.  Solid Security System

Along with protecting your workers from injury, protecting your inventory is just as important for a well-run operation. When items are stored in one location with technology designed to account for all material movement, maintaining inventory control becomes easier. Access to the machine can be restricted with a keycard or keycode authorization, and every interaction with the system is logged for higher visibility.

You can even set permissions to control who has access to each individual tray, ensuring that only the necessary personnel have access. This level of control enhances security and increases accountability for your team.

Want to learn more about these automation solutions?

These automation solutions from Hanel are ideal for manufacturing facilities. By allowing for a safe and flexible setup, these automation solutions can bring your facility to the next level. Reach out to our team at Industrial Shelving Systems to learn more about how a VLM or carousel can integrate into your manufacturing facility. Give us a ring at 1-800-875-6201 or reach out to us here to get started.