Rebuy Enhances Efficiency, Saves Space, and Improves Picking with Modula Lifts

Rebuy Case Study Summary

Rebuy, originally founded as Trader Game in 2004, began as a platform for trading computer games before expanding into media and electronics.

Facing a growing inventory and increasing operational costs, Rebuy needed a solution to enhance space efficiency and minimize labor requirements. By integrating 36 Modula Vertical Lift Modules (ML50D), Rebuy eliminated manual storage inefficiencies, reduced the overall warehouse footprint, and streamlined picking operations. The Modula units significantly improved productivity and created a more efficient, cost-effective warehousing system.

Today, approximately 40-50% of their daily operations run through the VLMs, with plenty of capacity for future growth.

The Challenge

Rebuy initially relied on a labor-intensive warehousing system with multiple levels of shelving, requiring employees to walk long distances each day to retrieve and store items.
The traditional setup posed several challenges, including high labor costs, long picking times, and the need for frequent inventory checks. Building an additional warehouse using the same racking methods would have resulted in increased staffing needs and costly rental fees. Rebuy needed a more efficient solution to optimize space, reduce labor costs, and improve overall inventory management.

The Solution

In April 2022, Rebuy chose to modernize its warehouse operations by installing 36 Modula Vertical Lift Modules (VLMs).
The installation began in August 2022, and by June 2023, all units were certified and fully operational. The Modula VLMs were installed alongside their existing shelving system, allowing them to efficiently manage both new and legacy inventory.

Each unit features dual opposite bays, providing two access points for flexible and efficient operations. Standing at 38′ (12 meters) high, the Modula Lifts effectively utilize the available vertical space of the facility, enabling Rebuy to avoid the high costs associated with building an additional facility.

The entire warehouse and picking process is integrated through the Modula WMS Link software, which works seamlessly with Rebuy’s warehouse management system.

Using Rebuy’s software, the operator selects items from prepared boxes and determines the precise storage location. The units then prepare the trays for retrieval. Items are scanned during placement, making them instantly visible in Rebuy’s online shop

Workers use handheld devices that direct them to specific trays, with each tray typically containing three to four items. This setup optimizes the picking process and ensures a smooth rotation of inventory. Conveyor belts further improve picking and storage workflows, reducing manual transport across the facility. On average, one worker manages six Modula lifts at a time, handling up to 1.5 million items currently stored in the Modula units.

With VLMs automating much of the physical operation, employees now focus more on quality control and supervision rather than labor-intensive tasks.

Another important consideration during Rebuy’s decision process was the flexibility and scalability of the Modula Lift design. The modular approach allowed them to expand warehouse capacity incrementally without disrupting logistical processes. This phased installation ensured smooth transitions, operational efficiency, and the ability to scale alongside future growth.

With a total storage capacity of nearly 3 million items, Rebuy is well-positioned for future growth. The Modula VLMs have led to increased productivity and optimized space usage. ReBuy can now pick over 300 items per hour from the Modula lifts, compared to 200-250 items per hour from standard shelving. By organizing items based on turnover rates and using the VLMs’ capacity, Rebuy has achieved greater efficiency and faster picking times, effectively managing increasing volumes.

Key Features of the Rebuy Case Study:

• Space Optimization: With 36 Modula ML50 D units Rebuy reduces warehouse footprint by over 60%.
• Increased Productivity: Employees now retrieve over 300 items per hour, compared to 200-250 items from traditional shelving.
• Real-Time Inventory Management: Modula Link software integrates with Rebuy’s existing system, providing real-time inventory and reducing discrepancies.
• Flexibility and Scalability: The modular design allowed phased installation, preventing logistical interruptions during expansion.
• Enhanced Security and Efficiency: Automated vertical storage prevents unauthorized access and reduces picking errors, improving inventory control and accuracy.