At Hersill, continuous improvement is one of our core principles. We constantly strive to optimise our processes, ensure the safety of our staff and improve operational efficiency. As part of this commitment, we have introduced a vertical storage system at our premises, an advanced technological solution that enables us to manage storage more effectively, optimise workflow and improve ergonomics in the workplace.
Iván Castaño, continuous improvement coordinator at Hersill, with over 20 years’ experience at the company, points out that this automated system has been implemented to store the components required for manufacturing the products. “This system, using a central lifting platform, can move the trays from their internal storage positions to the operators’ bay for the retrieval and replenishment of materials, in accordance with the ‘goods-to-man’ principle,” explains Castaño. He also emphasises that this implementation has been one of the most significant in terms of the resources and time invested.
Optimisation of space and better organisation
One of the main benefits of this vertical lift is its ability to make the most of the available space. In many industrial facilities, storage tends to expand horizontally, taking up large floor areas and hindering movement within the workspace. By implementing this system, we can utilise the height of the warehouse, allowing for greater storage capacity without the need to increase the floor space occupied.
“The choice of this storage system was driven by the need to optimise space without compromising storage capacity. With Modula, we found the solution “a comprehensive solution from a company with extensive experience, specialising in the manufacture of automated storage systems,” explains Castaño. The new system allows for the storage of up to 22.02 m³ in a space of just 9 m², with 40 trays available and a load capacity of up to 500 kg per tray.
Faster access and reduced search times
One of the challenges in warehouse management is the time spent searching for and retrieving goods. With traditional systems, warehouse staff have to walk up and down aisles, locate products on shelves and move them manually, which can cause delays and reduce productivity.
“The way the system works makes it possible to significantly reduce set-up times. “It can take anywhere from a few seconds to a maximum of 30 seconds to move the trays if they are at the furthest point,” explains Castaño. Furthermore, Thanks to the integration of Modula’s WMS software with Hersill’s ERP system, stock management has been optimised and the speed of searching for product references has been improved.
Greater accuracy and control over stock levels
Inventory control is a key aspect of any industrial business. Traditional systems rely heavily on manual management, which can lead to errors in the location, counting and retrieval of products. These errors can result in material losses, production delays and difficulties in order planning.
“The traceability of materials has been significantly improved by this system, reducing errors and optimising the organisation of stored products. Furthermore, 9 0% traditional containers, allowing for better visibility and access to the materials,” says Castaño.
Safety and ergonomics for workers
Another key aspect of installing this vertical lift is the improvement in our team’s working conditions. In traditional storage systems, workers have to manually lift and move heavy goods, reach high shelves or perform repetitive movements that can lead to fatigue or muscle injuries.
According to Castaño, the new system offers an ergonomic and safe solution: “The transport trolleys enable operators to remove fully loaded trays from inside the warehouse and transport them easily to the assembly tables. This reduces physical strain and minimises the risk of muscle injuries.” Furthermore, the system is equipped with safety barriers anti-intrusion photocells, an emergency stop button and an automatic diagnostic system to ensure maximum safety.
Energy efficiency and reduced operating costs
Optimising storage not only has an impact on productivity, but also on energy efficiency and the reduction of operating costs. Automated systems, such as this vertical storage system, enable a more rational use of resources, reducing energy consumption compared with traditional storage methods.
“Thanks to the integration of this system, we have managed to reduce the visual footprint, whilst optimising lighting and climate control within the warehouse. This not only reduces the environmental impact, but also improves long-term operational profitability,” explains Castaño. Furthermore, the implementation of electrostatic discharge (ESD) protection measures has been a key factor in maintaining the quality of the products manufactured at Hersill.
Another step towards the future of manufacturing at Hersill
The introduction of the automated vertical storage system marks a milestone in the evolution of our production processes. This solution has not only optimised materials management and reduced set-up times, but has also improved safety and ergonomics for our staff, ensuring a more efficient and safer working environment.
However, at Hersill we understand that innovation is not a destination, but a path of continuous improvement. The experience gained from this implementation enables us to continue exploring new technologies and methodologies that strengthen our ability to adapt to the demands of the healthcare sector.
We will continue to focus on solutions that enable us to manufacture medical equipment to the highest quality standards, contributing to the wellbeing of healthcare professionals and patients worldwide. This development is just another step forward in our mission to combine tradition, innovation and excellence in each of our products.
Frequently Asked Questions (FAQs)
¿Qué es un almacén vertical automatizado y cómo funciona?
It is a smart storage system that optimises space by utilising the available height and moves the trays via a central lift to the operator, based on the ‘goods-to-person’ principle.
How much space can you save with a vertical storage system?
This system enables a dramatic optimisation of industrial floor space, allowing up to 22 m³ of material to be stored in just 9 m² of floor space thanks to the use of high-capacity trays.
What are the benefits of integrating WMS software with an ERP system?
It enables real-time stock management, automates inventory control, reduces location errors by 90 per cent and speeds up order fulfilment times.
