Solution Profile: Recovered Floor Space Reduced Walk and Search Time up to 60% Items Presented at an Ergonomic Height Productivity Increased 40%

A medical device manufacturer in Ohio was faced with the need to increase productivity while protecting the company’s most valuable asset; their personnel. The company fulfilled this need by installing two Vertical Lift Modules (VLMs). By using the VLMs throughput was increased and workers were able to ergonomically pick orders.

Recovered Floor Space
Previously, the company had used a triple-tiered shelving system. The old shelving system was designed with the receiving operation at the top of the system’s mezzanine. This location caused extensive product handling, with some cartons being moved and restacked up to five times before they were delivered to the correct storage location. After installing the VLMs the recovered floor space allowed the company to relocate the receiving operation to the ground floor only a few feet from the receiving dock. “These VLMs allow us to offer [employees] a more productive way to do their jobs, as well as a safer way to do it.” stated the Senior Planner.

Items Presented at an Ergonomic Height
According to the Senior Planner, “Our personnel are our most valuable asset, and their safety and health are primary concerns.” The VLMs are designed to present stored items at an ergonomically correct height for safe, efficient order picking. By having items brought to this “Golden Zone” positioning, usually about 39 inches above floor level, the company has seen a reduction in lost time caused by product handling injuries.

Reduced Walk and Search Time up to 60%
The shelving storage system used by the company had required employees to spend a significant amount of time walking the aisles and searching shelves to fill orders. “The existing system required too much human handling and lifting of boxes,” said the Senior Planner. The vertical design of the newly installed VLMs delivers product directly to the operator allowing them to fill orders without walking the aisles. The installation of the VLMs has reduced the walk and search time up to 60%.

Productivity Increased 40%
Since the medical device manufacturer installed the VLMs in their facility not only are conditions more safe, they have seen a significant increase in productivity. The service parts department has increased its workload by up to 40% wihtout the need to hire additional staff. “The VLMs have certainly helped us improve our internal processes and procedures and meet our growth plans,” commented the Senior Planner.

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