Solarcraft Protects Electrical Components and Achieves First-Year ROI with Modula VLMs
Case Study Summary
To improve storage efficiency and inventory control, Solarcraft installed two Modula ML75D Vertical Lift Modules, purchasing its first unit in 2023 and a second in 2024. Today, the VLMs help protect high-value inventory, streamline material picking, support same-day spare-parts fulfillment, and integrate with Solarcraft’s ERP system. The investment delivered a return on investment within the first year.
The Challenge
As Solarcraft expanded, its existing storage area could no longer keep up with the company’s growth. Electronic components were stored in a locked cage that occupied valuable floor space, while nearby fabrication processes created dust that could settle on stored equipment and packaging.
The company also needed greater control over high-value and customer-supplied materials. High-value items account for nearly half of Solarcraft’s total warehouse inventory, making security, cleanliness, and traceability especially important.
Operational demands added another challenge. During peak season, each job can require approximately 50 to 80 different materials, while the team may manage 10 to 15 jobs per day and stage material four to six weeks in advance. Solarcraft needed a storage solution that could support this volume while improving organization and access to inventory.
The Solution
Solarcraft installed two Modula ML75D Vertical Lift Modules, purchasing its first unit in 2023 and adding a second in 2024. Each VLM is configured with 50 trays and an Internal Dual Tray Delivery Bay, giving the team organized access to the large number of components required for daily production.
At the picking bay, the Alphanumeric LED Bar guides operators to the exact compartment where material is stored, helping streamline staging and retrieval. Additional features, including a Barcode Reader, Sliding Operator Console, and Automatic Closing Door, support accurate identification and controlled access during picking.
Modula WMS Premium integrates with Solarcraft’s ERP system so picked material is automatically issued to the appropriate job, improving inventory control and traceability. The VLMs also help the team respond quickly to spare-parts requests, allowing parts to be retrieved within minutes to support Solarcraft’s goal of same-day shipment.
Key Results of Solarcraft Case Study:
- First-Year ROI: The first Modula VLM delivered a return on investment within its first year, contributing to Solarcraft’s decision to purchase a second unit in 2024.
- Improved Inventory Control: Enclosed storage helps protect high-value and customer-supplied materials while limiting discrepancies and maintaining traceability.
- Cleaner Component Storage: Electrical components are protected from dust and production debris, keeping material clean and ready for use.
- Faster Spare-Parts Fulfillment: Parts can be retrieved within minutes, helping Solarcraft support same-day shipment for spare-parts orders.
- More Usable Floor Space: Consolidating inventory into the VLMs freed space for production, an additional conference room, office space, and storage.
- Streamlined ERP Integration: Modula WMS integrates with Solarcraft’s ERP system so picked material can be automatically issued to the appropriate job.
Technical Information:
- 2 ML75D Units: Each with 50 trays, a height of 22.64 ft (6,900 mm), and a maximum tray load capacity of 1,654 lbs (750 kg).
“The great thing about the Modula is that it keeps everything clean. Because it’s an enclosed space, we’re not dealing with dust fall or debris from production. Our electrical components are kept clean and ready to go when they hit production.” – Rebekah Bookout, Materials Coordinator
“Our CEO’s philosophy is to get a part out the door same day. The VLM makes it happen where we can actually pull a part within a few minutes, and get that part out same day.” – Fredi Mendez, VP of Supply Chain Quality & Safety
