Smart warehouse solution for storing components and spare parts in the automotive industry

Overview

Heyco is a company specializing in the design and manufacturing of molded wire protection products and components for the automotive industry.

Fast custom design capabilities combined with high-volume production capacity help turn challenging just-in-time production deadlines into reality. Heyco’s manufacturing facility in Toms River, New Jersey, uses two Kardex Megamat vertical carousel systems to manage inventory of more than 18,000 sample SKUs.

Challenges

After storage capacity reached its limit, storing, managing, picking, and moving sample orders became a complicated and time-consuming process. Previously, Heyco relied on 20-year-old carousel systems to manage sample inventory, and frequent interruptions increasingly extended sample order processing times. “Sample orders are sometimes a customer’s first order with Heyco, so delivering the correct items quickly is extremely important,” said Colleen Faulknor, Vice President of Administration at Heyco.

Solution

Heyco installed two new Kardex Megamat automated storage systems in the sample management area. The units were configured with trays and bins to maximize storage density.

“With the Kardex Megamat, we can process the same number of orders faster and have increased our storage capacity,” Faulknor noted.

The previous carousel units were 20 feet tall and provided 1,792 storage locations. The new Kardex Megamat systems are 24 feet tall and provide 4,788 storage locations. As a result, the company increased sample storage capacity by 167% without expanding the installation footprint.

Scope of Delivery

• 01 Kardex Megamat automated storage system
• Logicontrol warehouse management software

Benefits Achieved

167% increase in storage capacity

By deploying two new Kardex Megamat systems, Heyco increased sample storage capacity by up to 167% without expanding floor space. The new units, at 24 feet tall, provide up to 4,788 storage locations compared to 1,792 locations in the previous systems. This enables the company to sustain and grow its sample program for years to come without space constraints.

Higher throughput

With optimized tray and bin configurations, the Kardex Megamat system reduces sample order processing time. Operators simply press a button and the system automatically brings the correct storage location to the access point, enabling faster and more accurate picking without unnecessary walking. As a result, daily order throughput has increased significantly while improving warehouse staff productivity.

Reduced downtime

The new systems are regularly maintained and operate reliably, helping Heyco nearly eliminate unplanned downtime. Minimizing downtime not only improves operational performance but also ensures a positive customer experience from the very first sample order.