GF Machining Solutions Employs VLMs
Global machine-tool maker adds Modula’s VLM’s and reduces floor space needs by 50%
Case Study Summary
GF Machining Solutions is a world leader in the supply of machines, solutions for automation, services for the production of molds and tools and for the production of high precision components. The company has a sales and support wing in Lincolnshire, Illinois, including a logistics hub that houses items to be shipped overnight to any address in North America.
Outdated storage equipment and a growing inventory made it difficult for them to provide same-day shipping to their customers. With the installation of Modula vertical lift modules and supporting software and picking aids, GF was able to store its inventory in 50% less space and increase its productivity and accuracy to deliver items to their customers quickly and reliably.
The Challenge
The GF Machining Solutions logistics facility was expected to ship 99%+ of ordered items the same day, but this was particularly difficult to achieve with orders placed late in the day. Growth and acquisitions had expanded their inventory. Their old materials handling equipment not only took up a lot of floor space, it required constant repairs and maintenance, resulting in increased downtime and
trapped inventory. An inefficient storage configuration resulted in bottlenecks in the picking and shipping processes.
GF decided it needed a modern warehouse solution that could meet their efficiency and storage needs for the foreseeable future, as well as integrate with their ERP and WMS systems.
The Solution
After extensive research of alternatives, GF Machining Solutions settled on three Modula VLM, each installed in less than a week. A Modula WMS was added and inventory data was loaded so the interfaces were available even before the VLMs were in place without any downtime in operations. The VLMs were equipped with double-delivery bay options and Modula’s put-to-light batch picking system. By taking advantage of the vertical space in their facility, GF could store its 12,000 items of inventory in half the floor space previously used. This allowed them to reconfigure the warehouse to allow a separate area for the picking and shipping processes. The visual aids helped speed up the time it took operators to locate and retrieve the parts, and the enclosed nature of the VLMs meant the parts – worth several million dollars – were now safe and secure.
GF has been delighted with how the new system is performing. Director of Operations Mark Sanhamel appreciates the dual-delivery presentation. “We felt that was a unique selling point because while someone was picking, the next part and tray they needed was already positioned for them. It helped increase the amount of picking time with a tight crunch time in the afternoon.
Operations Manager Stan Pokrzywa touts the easy and intuitive operation of the VLMs: “I can bring somebody new to the floor and I can have them picking parts in less than 5 minutes.” Adding up all the benefits — improved accuracy, picking speed and ease of use – GF is satisfied with their decision.
“I would absolutely recommend the Modula unit to other people who have similar needs for meeting tight demands for customers, for picking accuracy, who can’t afford to have mis-shipped parts, have inaccuracies or don’t have the luxury of waiting for parts to be delivered to them,” he says. “We have been very happy with the reliability and support.”
Stan Pokrzywa – Operations Manager, GF Machining Solutions
