Jamesway Centralizes 4,000 Spare Parts with Modula Vertical Lift Modules
Case Study Summary
To centralize its spare parts inventory and make better use of nearly 40 feet of available ceiling height, Jamesway installed two Modula ML75D Vertical Lift Modules. Today, the VLMs manage approximately 4,000 SKUs, improve picking speed and accuracy, and enhance operator safety and ergonomics. Once fully utilized, Jamesway estimates they will recover up to 10,000 sq. ft. of floor space.
The Challenge
With customers in more than 100 countries, Jamesway depends on an efficient spare parts operation to keep orders moving quickly.
Before Modula, parts were stored in multiple locations throughout the plant, requiring employees to spend valuable time locating and retrieving items before bringing them to shipping. This decentralized approach also made inventory control more challenging.
As the business grew, Jamesway needed to increase storage capacity and productivity while controlling rising costs and avoiding the need for additional floor space. With nearly 40 feet of ceiling height available, the company saw an opportunity to utilize its existing vertical space while creating a faster, safer, and more accurate picking process.
The Solution
Jamesway installed two Modula ML75D Vertical Lift Modules, taking advantage of nearly the full height of its 40-foot facility to centralize approximately 4,000 SKUs within a compact footprint. Instead of searching for parts throughout the plant, operators now receive inventory directly at the picking bay. The Dual Internal Picking Bay keeps operations moving by preparing the next tray while the operator works from the current one, reducing wait time and helping speed up picking and shipping.
Modula WMS Premium integrates with Jamesway’s existing ERP system to improve inventory control and accuracy. At the picking bay, the Alphanumeric LED Bar displays the part number and quantity, while the Laser Pointer identifies the exact location on the tray. Parts are delivered at an ergonomic working height, eliminating ladders and overhead reaching, while the intuitive interface allows new operators to learn the system within just a few hours. Once parts are picked, the Modula Put to Light System directs operators to the correct order location, helping streamline sorting and fulfillment.
The benefits extend beyond the technology itself. Jamesway praised the experience of working with Modula, from the straightforward implementation process to responsive support and fast installation. Amir Ebrahimi, Chief Operating Officer at Jamesway, described the experience: “The process was very straightforward, and working with the team, especially the sales and installation teams, was easy. The installation was very quick, and I was impressed. We got the support we needed.”
Key Results of Jamesway Case Study:
- Space Optimization: By utilizing nearly the full height of its facility, Jamesway expects to recover up to 10,000 sq. ft. of floor space once both VLMs are fully utilized.
- Centralized Inventory: Approximately 4,000 SKUs are now consolidated within two VLMs, replacing inventory previously stored across multiple locations throughout the plant.
- Faster Picking & Shipping: Goods-to-person delivery and the Dual Internal Picking Bay reduce operator travel and wait time, helping parts move more efficiently from storage to shipping.
- Greater Picking Accuracy: Integration between Modula WMS Premium and Jamesway’s ERP system improves inventory control, while the Alphanumeric LED Bar, Laser Pointer, and Put to Light System guide operators through the picking and sorting process.
- Improved Safety & Ergonomics: Parts are delivered directly to operators at an ergonomic working height, eliminating the need to climb ladders or retrieve inventory stored at or above shoulder level.
- Faster Operator Training: An intuitive interface makes the VLMs easy to learn, with new operators becoming comfortable using the system within just a few hours.
Technical Information:
- 1 ML75D Unit: With 60 trays, a height of 37.07’ (11,300 mm), and a tray load capacity of 1,653 lbs (750 kg).
- 1 ML75D Unit: With 58 trays, a height of 35.76’ (10,900 mm), and a tray load capacity of 1,653 lbs (750 kg).
“If you’re looking to utilize space, looking for the ergonomic safety of your employees and the ease and accuracy of picking, I would definitely recommend the VLM.” – John Copping, Production Manager
“The process was very straightforward, and working with the team, especially the sales and installation teams, was easy. The installation was very quick, and I was impressed. We got the support we needed.” – Amir Ebrahimi, Chief Operating Officer
