Vertical Lift Modules (VLM)

Space savings of 60-75% result from vertical storage to 40+ feet and elimination of aisles. A single VLM occupying 15-30 square feet can replace 200-400 square feet of shelving, freeing valuable floor space for productive operations. Vertical expansion enables facilities to add capacity without building expansion, particularly valuable in constrained urban locations or expensive real estate.

Productivity improvements of 2-3x come from automated tray delivery eliminating walking and searching time. Workers remain at ergonomic workstations while the VLM delivers items, reducing fatigue and improving pick rates to 100-200+ lines per hour. Ergonomic benefits presenting items at comfortable heights reduce injury risks and improve worker satisfaction.

Inventory accuracy exceeds 99% through controlled access and automated tracking. Secure storage with access control prevents unauthorized removal, valuable for high-value items or controlled substances. Environmental protection with optional sealed enclosures protects sensitive items from dust, moisture, or temperature variations.

Manufacturing uses VLMs for storing components, tools, and spare parts near production lines. Just-in-time delivery of parts reduces work-in-process inventory. Tool cribs manage thousands of tools with automated tracking and controlled access. Kitting operations assemble components for production orders.

Maintenance and repair operations in aerospace, automotive, and industrial sectors leverage VLMs for managing thousands of spare parts. Rapid retrieval enables quick order fulfillment when parts are needed. Inventory tracking supports maintenance planning and procurement.

Healthcare and pharmacy operations use VLMs for medication storage and dispensing. Controlled access and audit trails support regulatory compliance. FIFO rotation ensures proper product dating. Secure storage prevents theft or unauthorized access to controlled substances.

Electronics and small parts distribution employs VLMs for managing diverse SKU assortments in minimal space. High SKU density supports thousands of products in compact footprints. Batch picking for multiple orders improves fulfillment efficiency.

Building requirements include adequate ceiling height (15-40+ feet preferred), normal floor capacity (500-1,000 PSF), and access for installation. Modular sizing allows selection of appropriate height and capacity for specific needs. Capital investment of $50K-200K per unit with typical payback of 2-4 years through space savings and productivity improvements.

Tray configuration determines storage efficiency. Adjustable tray heights (3-24 inches) accommodate varying product dimensions. Tray subdividers organize small items within trays. Weight capacity (typically 500-1,500 pounds per tray) must accommodate actual loads.

Integration with picking stations, inventory systems, and facility infrastructure requires planning. Ergonomic workstation design maximizes picker productivity. WMS or ERP integration provides real-time inventory visibility and automated replenishment. Electrical requirements are modest (typically 110-220V single phase).

Slotting optimization places high-velocity items in the most accessible tray positions (middle heights) to minimize extractor travel. ABC analysis guides placement decisions. Dynamic slotting adjusts locations based on changing velocity patterns.

Batch picking groups orders to minimize tray retrievals. Pick-to-light or voice picking systems integrated with VLMs improve accuracy and speed. Replenishment planning ensures adequate stock levels without overfilling trays.

Preventive maintenance includes monthly inspections, quarterly lubrication, and annual professional service. Spare parts inventory enables rapid repairs. Well-maintained VLMs operate reliably for 15-20 years.

Key metrics include picks per hour (target 100-200+), space savings (square feet freed), inventory accuracy (target 99%+), and system uptime (target 98%+). ROI materializes over 2-4 years through space savings and labor productivity. Ergonomic improvements and reduced travel time validate the investment.

By implementing VLMs with attention to tray configuration, slotting optimization, and workstation design, facilities achieve significant space savings and productivity improvements for small parts storage and order fulfillment operations.