New Fer, a Hardware Distributor Increases Picking Productivity with Modula VLMs
Case Study Summary
New Fer is an Italian distributor specializing in hardware, fasteners, tools, and industrial supplies for businesses, manufacturers, and mechanical workshops. Based in Vicenza, Italy, the company offers a wide range of products, including bolts, chemicals, safety equipment, and technical components. Since coming under new ownership in 2018, New Fer has focused on modernizing its operations, improving customer service, and creating a more efficient working environment for its employees.
As part of this transformation, New Fer installed six Modula vertical lift modules (VLMs) to optimize storage space, streamline order picking, and improve inventory management. With Modula, the company increased its daily picking output from approximately 200-250 to 500-800 lines, more than doubling productivity without adding warehouse personnel. The new system has also accelerated order fulfillment and improved customer service.
The Challenge
Before implementing Modula, New Fer stored its extensive inventory of hardware and industrial supplies on traditional shelving distributed across multiple warehouse zones. Preparing an order required operators to move between different areas, manually locating and collecting products. This process involved considerable walking and physical handling, making picking operations time-consuming and labor-intensive.
Checking product availability was equally challenging. When customers called or visited the store, employees often had to physically inspect the shelves to confirm whether an item was in stock, delaying responses and order preparation.
To improve operational efficiency and meet growing customer expectations, New Fer needed a solution that could simplify picking activities, provide better inventory visibility, and accelerate order fulfillment.
The Solution
To modernize its warehouse operations, New Fer began implementing Modula automated vertical storage systems in 2020. The company installed six VLMs, including four Modula Slim units and two Modula Lift units, to make better use of its available vertical space and improve inventory organization.
Equipped with laser pointers and alphanumeric LED bars, the systems guide operators during picking operations. Modula WMS provides computerized inventory management, allowing employees to monitor product locations, quantities, and stock availability.
The new picking process also incorporates picking carts. Operators retrieve most of the required items directly from the Modula systems before collecting any remaining products from conventional shelving. This approach simplifies order preparation and minimizes unnecessary movement throughout the warehouse.
Key Features of the New Fer Case Study
- Increased Picking Productivity: Daily picking output increased from 200-250 to 500-800 lines with the same number of operators.
- Optimized Storage Space: Vertical storage maximizes available space and reduces reliance on conventional shelving.
- Improved Inventory Management: Modula WMS provides immediate access to product locations and stock availability.
- Faster Order Fulfillment: Automated picking and streamlined workflows reduce order preparation times.
- Enhanced Customer Service: Employees can quickly confirm product availability and prepare materials for customer pickup.
“Before Modula, we handled around 200 to 250 picking lines per day. Today, with six vertical warehouses, the same number of operators can manage between 500 and 800 picking lines daily.” –
Nicola Bisello – CEO – New Fer
“One of the greatest benefits is that when a customer calls, we can immediately tell them whether a product is in stock. We’ve also significantly reduced order preparation and delivery times.” –
Daniele Callegaro – Sales Counter – New Fer
