Royal Canin Korea Optimizes Spare Parts Management with Modula Vertical Lift Modules
Royal Canin Case Study Summary
Royal Canin Korea is a recognized leader in the pet food industry, known for its uncompromising standards of quality and safety. Operating in a highly regulated environment compliant with Class 1000 cleanroom standards, the company needed a flawless system to manage spare parts for its automation equipment. By replacing traditional pallet storage with Modula Vertical Lift Modules (VLMs), the facility eliminated the risks associated with forklifts and created a fast, safe logistics workflow that perfectly aligns with their strict hygiene requirements.
The Challenge
Before adopting Modula Automated storage and retrieval solutions, the company stored spare parts and maintenance materials on traditional pallets. To retrieve even a single small component, operators had to use forklifts to reach uncomfortable and dangerous heights. This approach presented several critical issues. First, it caused inefficiencies and required non-ergonomic physical exertion from the staff. Moreover, it had led to minor workplace accidents over the years. Additionally, the open and disorganized storage on pallets starkly contrasted with the rigorous cleanliness, order, and safety demands of the plant’s controlled contamination environment (Class 1000).
The Solution
To address these challenges at the root, Royal Canin Korea modernized its logistics layout by installing two Modula Lift ML50D vertical lift modules. Each unit features 71 trays.
To maximize picking accuracy and ease of use, Modula equipped the units with:
- A laser pointer, which visually guides the operator by highlighting the exact location of the item to be picked.
- A sliding console (Co-Pilot) in the bay, making operations extremely intuitive and fast.
With this new configuration, all critical components are now highly organized, protected within an enclosed structure, and instantly accessible without the need for heavy machinery.
The Result
The benefits for the Korean facility were tangible from day one. The most significant impact was on workplace safety. The drastic reduction in forklift usage led to a significant drop in the risk of warehouse accidents.
Additionally, the “goods-to-person” principle revolutionized ergonomics, as items are now automatically delivered to the operator at the ideal height. Operational efficiency also saw a rapid increase. Maintenance technicians no longer waste time searching for parts or moving entire pallets to find a single spare component, ensuring faster maintenance and greater continuity for the production line.
Key Benefits Highlighted in the Royal Canin Case Study
- Enhanced Workplace Safety: Drastic reduction in forklift use and prevention of warehouse accidents.
- Improved Ergonomics: Elimination of dangerous bending and reaching thanks to the ergonomic picking bay.
- Maximum Protection and Cleanliness: Enclosed storage protects components from dust and contamination. Thus, it fully complies with Class 1000 cleanroom standards.
- Operational Efficiency: Workers reduced picking times for spare parts to mere seconds, supporting continuous production.
- Zero Picking Errors: The integration of the laser pointer and sliding console ensures immediate and accurate component identification.
