HERO Intelligent has developed a smart warehousing and logistics solution for a globally recognized manufacturer of power tool components. The company constructed a new five-story production facility alongside an automated high-bay warehouse. By seamlessly integrating the warehousing system with the production workshops, the solution enables automated material storage, receiving, dispatching, and production-line delivery—optimizing internal logistics and enhancing the synergy between warehouse management and production.

Project Pain Points:

High complexity in material storage and management: The diverse specifications and varying dimensions of power tool components place high demands on warehouse space planning, slotting management, and categorized storage.

Fragmented layout of raw material storage and production workshops: The physical separation between the raw material storage area and the multi-story production workshops results in long distribution routes and multiple handling stages, complicating the management and delivery of production materials.
Reliance on manual labor for material handling: Traditional forklift-based delivery requires manual intervention, leading to limited transport efficiency and high physical strain on personnel. Furthermore, frequent forklift traffic creates operational safety risks.

Project Scope:

The project includes a high-bay warehouse for large-sized raw materials and a "Miniload" automated storage system for smaller items. The large-item facility is equipped with two double-mast, double-deep stacker cranes and four rail-guided vehicles (RGVs), providing 3,128 pallet positions. The Miniload facility features four double-mast, double-deep stacker cranes and four multi-level lifts, offering 40,000 storage locations. Through the efficient integration of automated warehousing equipment and production workshops, the system achieves automated storage and precise distribution for a wide variety of materials.

Project Highlights:
1. High-bay warehouse design for maximized space utilization: The implementation of both a large-item high-bay warehouse and a Miniload system addresses the need for categorized storage of diverse materials, ensuring optimal use of available warehouse space. 2. Seamless Integration Between Warehousing and Production: By coordinating automated storage and conveying equipment, we establish a logistics link between the warehouse and the five-level production facility, enabling automated material handling and efficient distribution.

3. Digital System Integration for End-to-End Automation: Through integration with the client’s MES and ERP systems—combined with the seamless interoperability of the Hangrui WMS/WCS—we achieve full-process automation for material storage, scheduling, and inbound/outbound operations.