Background
In the machining industry, the timely and accurate supply of tools and materials directly impacts production rhythm and machine utilization. A machining enterprise (hereinafter referred to as “the Company”) frequently handles large volumes of tool holders, inserts, and various auxiliary materials in its daily operations. The traditional storage method could no longer meet growing production demands, and an intelligent storage solution was urgently needed to improve efficiency and ensure quality.
Pain Points
The production rhythm in machining workshops depends heavily on the timely and accurate supply of tools and materials.
In traditional operations, tools are stored randomly, with tool holders and inserts mixed together. This not only makes tools more vulnerable to impact and damage, but also forces operators to spend a great deal of time looking for the right tool.
At the same time, the tool loading process lacks precise positioning and relies mainly on manual experience, which creates a higher risk of error.
In addition, tool inventory data cannot be synchronised with the tool management system in real time, affecting tool preparation decisions and production scheduling. Together, these pain points restrict equipment utilisation and machining quality.
Solution
To solve these issues, the company deployed two Modula vertical lift modules, each 9.7 metres high. With a combined footprint of less than 15 square metres, the two units provide approximately 167 square metres of effective storage area, significantly improving space utilisation.
The two units have clearly defined roles:
- The first unit is a dedicated tool storage system for tool holders, inserts and other key components. Inside the tool storage unit, trays use tool-holder fixtures and metal dividers to classify and manage tools, effectively preventing impact, wear or loss. This tool storage unit is configured with 44 trays, including 12 trays fitted with tool-holder fixtures. Each tray layer can store more than 90 tool holders, with total capacity for more than 1,080 tool holders. The maximum load capacity of a single tray exceeds 750 kg.
- The second unit is used as a material storage system for various auxiliary materials. It is configured with 59 trays and stores both large and small standard bins, with total capacity for more than 650 bins.
Beyond the storage capacity of the hardware itself, Modula’s proprietary WMS warehouse management system is the key connector in the solution. Based on standardised interfaces, the system can be seamlessly connected to the company’s existing tool management system, enabling efficient communication and automatic linkage. The entire process does not rely on an additional intermediate platform or complex secondary development, ensuring clear workflows, stable logic and long-term system operability. Through this closed data loop, real-time inventory data from the tool storage system is automatically fed back to the tool management system for tool preparation decisions. Tool managers can understand the current types and quantities of available tool holders and inserts without manual stocktaking, greatly improving tool preparation efficiency and accuracy.
