Business Aircraft Manufacturer Reduces Warehouse Storage Footprint by 85% with VLMs
A business aircraft manufacturer was moving into a newly constructed facility in Broomfield, Colorado, in the Denver metro area, with less space available for warehouse storage. Southwest Solutions Group replaced approximately 2,000 square feet of mezzanine racks and shelving with two Kardex Remstar Vertical Lift Modules, creating a compact automated storage and retrieval system for warehouse picking, stocking, and inventory control.
Warehouse storage optimization project for a business aircraft manufacturer.
Completed for the customer’s newly constructed Colorado facility near Denver.
Storage area supporting inventory access, picking, stocking, and tracking.
Two Kardex Remstar Vertical Lift Modules replaced a mezzanine-based storage layout with a smaller automated footprint.
The available facility height supported 28-foot vertical lift modules for high-density warehouse storage.
The project focused on fitting storage into a smaller area while improving picking speed, inventory accuracy, and ergonomics.
A Facility Move Required More Efficient Warehouse Storage in Less Floor Space
A business aircraft manufacturer was moving to a newly constructed facility in the Greater Denver area with less space available for warehouse storage. The previous warehouse used stationary shelving above and below a mezzanine, occupying about 2,000 square feet and creating inefficient picking workflows.
The new facility had less floor space available for warehouse storage and inventory access.
The existing layout relied on stationary shelving above and below a mezzanine, which slowed picking and stocking.
The mezzanine storage area occupied approximately 2,000 square feet that could not fit the new warehouse plan.
Two 28-Foot Kardex Remstar VLMs Replaced the Mezzanine Storage Footprint
Southwest Solutions Group designed the warehouse storage optimization solution around the height available in the customer's new Colorado facility. Two Kardex Remstar Vertical Lift Modules replaced approximately 2,000 square feet of mezzanine and shelving, reducing the storage footprint to approximately 240 square feet while automating storage and stocking processes with Power Pick inventory management software.
Vertical Storage Using Facility Height
The 28-foot Kardex Remstar Vertical Lift Modules used the available building height to consolidate inventory into a much smaller warehouse storage footprint.
The Kardex Remstar Vertical Lift Modules automated storage and stocking workflows, supporting faster retrieval times and more efficient warehouse picking.
Power Pick inventory management software provided controlled access to inventory and full software-based tracking to improve inventory accuracy and warehouse efficiency.
Installation Was Coordinated with the Customer's New Facility Move
The project was driven by the customer's new construction and relocation timeline in Broomfield, Colorado. Southwest Solutions Group completed the automated storage and retrieval system project in approximately five months from purchase order issuance to final customer acceptance, with installation taking place between March 26, 2018, and April 13, 2018.
Confirm New Facility Storage Constraints
The team evaluated the reduced warehouse storage space created by the move to the newly constructed facility in the Denver metro area.
Design Around Available Vertical Space
The available building height supported two 28-foot Kardex Remstar Vertical Lift Modules, allowing the system to replace a large mezzanine footprint with high-density vertical storage.
Install the Automated Storage System
Two Vertical Lift Modules replaced approximately 2,000 square feet of mezzanine racks and shelving with approximately 240 square feet of automated storage.
Complete Software Integration and Customer Acceptance
Power Pick inventory management software was configured as part of the solution, and the project reached full customer acceptance approximately five months after purchase order issuance.
The Customer Reduced Its Warehouse Footprint While Improving Inventory Access
The automated storage and retrieval system helped the business aircraft manufacturer replace spread-out mezzanine shelving with compact vertical storage. The project reduced the warehouse storage footprint by approximately 85% while improving picking speed, inventory accuracy, ergonomics, and warehouse efficiency at the customer's Colorado facility.
The project replaced approximately 2,000 square feet of mezzanine racks and shelving with about 240 square feet of Kardex Vertical Lift Module storage.
Automated storage and retrieval significantly improved picking efficiency by delivering inventory directly to the operator instead of requiring travel through conventional shelving.
Power Pick inventory management software improved inventory visibility, tracking, and overall inventory accuracy while reducing manual handling.
Eliminating the mezzanine reduced stair climbing and improved ergonomics, creating a safer and more efficient warehouse environment for employees.
