PCS Company Boosts Accuracy and Capacity with Modula VLMs
Case Study Summary
PCS Company, based in Fraser, Michigan, has been a trusted supplier to North American mold makers for 75 years. Originally founded as R&S Tool, the company has grown to become the number one supplier to the mold-making industry, thanks to its focus on innovation, quality, and continuous improvement.
When faced with space limitations in their warehouse, PCS turned to Modula Vertical Lift Modules (VLMs) to expand storage capacity without relocating. By storing more than 5,000 parts vertically, roughly 40% of their total inventory, PCS increased efficiency, improved accuracy, and positioned itself for future growth.
The Challenge
With over 12,000 parts in inventory and limited warehouse space, PCS faced mounting challenges in keeping pace with customer demand. Traditional shelving layout consumed valuable square footage and forced employees to walk long aisles and use ladders to access high shelves. This not only slowed down operations but also increased safety risks.
Order accuracy was another critical issue. Mistakes in picking had serious consequences, as even a single error could damage long-term customer relationships. Reducing returns and improving order accuracy became a key priority. At the same time, PCS needed a system that would provide room to grow without the costly option of moving or expanding into a larger facility.
The Solution
To address its space and efficiency challenges, PCS integrated Modula Vertical Lift Modules into its warehouse operations. By transitioning to vertical storage, the company reclaimed thousands of square feet of floor space and consolidated over 5,000 parts, nearly 40% of its inventory, within the VLMs. This eliminated the need for additional shelving and avoided the cost of relocating or expanding.
The benefits were quickly felt across the business. Picking accuracy improved by around 40 percent, which reduced costly returns to single digits.
Productivity also increased, with the team now processing over 2,000 order lines per day, up from approximately 1,500. The VLMs’ guided picking features, such as the LED bar, simplify the process for operators and ensure that items are located quickly and accurately.
The VLMs also enhanced safety and ergonomics. Employees no longer need to climb ladders or bend to reach items, reducing physical strain and improving working conditions. The system’s intuitive interface makes training simple. New team members can be onboarded in just a few hours, an important advantage during peak periods.
As President Angela Elsie explained, “In a warehouse facility, square feet is your most valuable asset. You need to utilize it to its full potential, and these modules are a great solution.”
Key Benefits of Modula VLM
- Saves thousands of square feet of warehouse space by storing 40% of parts vertically
- Supports more than 2,000 order lines per day, up from 1,500
- Picking accuracy increased by 40%, reducing returns to single digits
- Improves safety by eliminating ladder use and reducing physical strain
- Easy to learn, with training completed in just a few hours
- Provides scalability and flexibility for PCS’s future growth
