SMI Maximizes Aerospace Production Capacity with Modula Vertical Lift Modules
Case Study Summary
Skilled Manufacturing Inc. (SMI) is a U.S.-based aerospace components manufacturer with approximately 150 employees. The company machines, inspects, and assembles high-precision parts for the aerospace industry.
As production needs increased, floor space became limited, putting pressure on SMI to either expand its facility or find more efficient ways to use existing space.
To address this challenge, SMI implemented three Modula Vertical Lift Modules (VLMs) to consolidate inventory, streamline picking, and reclaim valuable production space. The Modula systems not only improved efficiency and accuracy but also freed up enough floor space to add new machining centers, directly supporting company growth.
The Challenge
As SMI expanded production, floor space became a critical constraint. Inventory was stored on static racking systems that
took up a significant footprint. Operators had to manually search for parts, a time-consuming process that also contributed to errors and inefficiencies.
Without an alternative, SMI faced two costly options: scrapping its plan to add new machines or expanding the production floor. Both options threatened productivity and growth. The company needed a solution that could reduce space usage, simplify inventory management, and support a higher volume of production without sacrificing accuracy.
The Solution
To meet these needs, SMI implemented a Modula Lift MC75D and two Modula MA50 units. Each system is equipped with Internal Dual Delivery Bays for faster tray exchanges, along with an Alphanumeric LED Bar, Laser Pointer, and the intuitive Co-Pilot console. These features allows operators to quickly locate the correct parts and quantities, while minimizing errors.
Inventory Control Specialist Audrey Nelson explained how the system transformed her daily work: “The trays are brought to me. I don’t have to remember where everything is because we have thousands of parts. The laser pointer tells me exactly where to go. It saves me a lot of time, and I don’t even have to think about it—it’s wonderful.”
The space savings were immediate. By centralizing storage in the Modula units, SMI freed up more than 4,000 square feet of production space, enough for SMI to install four additional machining centers without expanding the facility. By keeping parts enclosed, the systems also improved cleanliness and safety, reducing contamination risks and helping maintain strict aerospace quality standards.
Reliability and local support were also key. “Not only is it U.S.-built, but also the serviceability,” said Production Line Manager Joe Carpenter. “We don’t have to wait for an international call. Modula has a 24-hour hotline, and usually within a couple of hours, we have a response. Almost never have we had a problem that put production down.”
Integration and training took just two weeks, making the transition seamless. Today, the Modula systems continue to enhance space utilization, increase accuracy, and support SMI’s growing aerospace production.
Key Benefits of Modula VLM
- Saved more than 4,000 square feet of production floor space
- Stores over 1,550 cubic feet of parts in just 154 square feet of footprint
- Increased efficiency with Internal Dual Delivery Bays for faster tray exchanges
- Improved picking accuracy through Alphanumeric LED Bar and Laser Pointer guidance
- Simplified daily operations with the user-friendly Co-Pilot console
- Reliable 24-hour U.S.-based technical support ensures uptime and peace of mind
