Case study
All in order, with more vertical space and no intermediate stock
Story courtesy of A. Ariu and G. Mazzola/Lamiera
Modula has made sheet metal component flow more efficient thanks to Salvagnini technologies that integrate planning, nesting, line-side kitting and digital quality control.
All in order, with more vertical space and no intermediate stock
Highlights
- Modula
Founded in 1987, Modula designs and manufactures automated vertical tray warehouses for space-efficient, goods-to-person storage. At its headquarters in Salvaterra di Casalgrande, Italy, the company produces highly configurable systems, with trays up to 7 m long and warehouse heights exceeding 20 m. - The challenges
Increasing product variety made weekly stock-based casing production difficult to coordinate, with components sorted into shipping kits only after processing. “The real challenge is not to produce more components, but to manage a growing variety of configurations while maintaining control of the flow,” says Marco Pellesi, Industrial Operations Director & CEO. - The solution
Modula uses six Salvagnini S4+P4 integrated punching and panel bending lines, three laser cutting systems, three press brakes (two robotized) and a P2 panel bender. Salvagnini OPS connects order-based nesting and kitting with manufacturing execution system planning and digital quality control. - The results
Casing production efficiency increased from approximately 50% in 2010 to 75%, while the Italian plant now produces more than 3,000 warehouses annually, averaging 12 per day. Order-based nesting and direct packing into shipping boxes eliminate intermediate stock handling; barcode-based checks verify kit contents before shipment.
