ATS Group - Merelbeke Belgium Electrical Components Automated Warehouse
⭐Key Features
- •Eight Vertical Buffer Module Kardex Compact Buffers with automatic inbound system
- •Integrated conveyor network connecting receiving, storage, and shipping zones
- •Automated bin transfer through first-floor openings to vertical storage
- •Combined automatic inbound processing with high-performance operator picking
- •40% of 13,000-article database stored in Kardex automated systems
📊Results & Benefits
- ✓Saved more than 50% floor space while storing more articles
- ✓Increased throughput from 500 to 900 orders
- ✓Reduced workforce requirements to one-third of previous levels
- ✓Achieved high-performance warehouse operations supporting business growth
- ✓Enabled efficient handling of fast-moving electrical components for projects and customers
🎯Challenges & Solutions
Traditional warehouse limiting throughput and space utilization for growing business
Implemented 8 Vertical Buffer Modules with automated inbound and conveyor integration
No available square meters for expansion in existing warehouse
Vertical storage solution stored more inventory on half the floor space
Need to optimize volume usage while increasing order processing capacity
Designed tailored ASRS combining automatic inbound with high-speed operator picking
📝Project Overview
Project Overview
ATS Group, a multidisciplinary technological group headquartered in Merelbeke, Belgium, faced operational challenges in their traditional warehouse as the business expanded across four main areas: electrical and automation projects, HVAC and energy solutions, mechatronics, and electrical components wholesale. The company needed to significantly improve warehouse efficiency to support rapid business growth while dealing with space constraints in their existing facility.
The core challenges included increasing throughput capacity, optimizing volume utilization, and managing the storage and distribution of approximately 13,000 different small electrical parts, predominantly fast-moving items distributed to projects and end customers. With no available square meters for expansion in the existing warehouse, ATS Group required an innovative solution that could maximize storage density while enhancing order processing capabilities.
After thorough analysis, Kardex was selected to design and implement a tailored automated storage and retrieval system. The solution needed to address both storage optimization and distribution efficiency while supporting the company's diverse technological operations and wholesale activities.
Technical Solution
Eight Vertical Buffer Module System
The centerpiece of the automation solution consists of eight Vertical Buffer Module Kardex Compact Buffers. These automated vertical storage systems provide high-density storage for ATS Group's electrical components, storing 40% of the company's 13,000-article database. The vertical orientation maximizes storage capacity within minimal floor space, directly addressing the company's space constraints.
Mecalux Shuttle System: Automated AS/RS for Boxes and Small Parts
Vendor: Mecalux
Key Features
The eight Vertical Buffer Modules provide exceptional space efficiency, enabling ATS Group to store more inventory on half the floor space previously required. This vertical storage solution was critical given the zero available expansion space in the existing warehouse.
The combination of automatic inbound processing with high-performance operator picking creates a balanced automation approach that leverages both machine efficiency and human flexibility. This hybrid design ensures optimal performance for handling diverse electrical components.
The integrated conveyor network creates a continuous material flow from receiving through to shipping, eliminating manual transportation and reducing handling time. This seamless connectivity between operational zones significantly improves overall throughput.
The system's capacity to store 40% of ATS Group's 13,000-article database demonstrates its strategic importance in the company's inventory management. This concentration of fast-moving items in automated storage optimizes picking efficiency for high-demand components.
The automated bin transfer through first-floor openings provides innovative vertical material handling that maximizes the facility's three-dimensional space utilization, creating operational efficiency in both horizontal and vertical dimensions.
Results & Benefits
The implementation has achieved remarkable space savings, with ATS Group saving more than 50% of floor space while actually increasing the number of articles stored. This space optimization resolved the critical constraint of no available expansion area.
Throughput has dramatically increased from 500 to 900 orders, representing an 80% improvement in order processing capacity. This enhanced throughput supports the company's business growth and expanding customer demands.
Workforce efficiency has improved significantly, with the automated system requiring only one-third of the previous workforce levels. This labor optimization reduces operational costs while maintaining higher output levels.
The warehouse now operates as a high-performing facility that can effectively deal with growing order volumes, providing ATS Group with the operational capacity to support continued business expansion across their four technological divisions.
The solution enables efficient handling of fast-moving electrical components for both project requirements and wholesale customer distribution, ensuring timely delivery and supporting customer satisfaction across all business areas.
Challenges & Solutions
ATS Group's primary challenge was the limitations of their traditional warehouse, which constrained throughput and space utilization amid business growth. The eight Vertical Buffer Module system with automated inbound and conveyor integration addressed this by creating a high-density, high-throughput automated storage solution.
The critical space constraint of having no available square meters for expansion in the existing warehouse was solved through vertical storage optimization. The Vertical Buffer Modules enabled storing more inventory on half the floor space, effectively doubling storage capacity without expanding the facility footprint.
The need to optimize volume usage while simultaneously increasing order processing capacity required an innovative approach. Kardex's tailored ASRS design successfully combined automatic inbound processing with high-speed operator picking, creating a balanced solution that maximizes both storage density and operational throughput.
System Integrator
Kardex served as the system integrator and solution provider for ATS Group's warehouse automation project. The company designed the comprehensive automated storage and retrieval system featuring eight Vertical Buffer Modules, automated inbound processing, and integrated conveyor network.
Kardex's approach was characterized by consistent project management and effective execution. ATS Group noted the positive experience working with Kardex, highlighting the availability of a single direct contact throughout the entire project from design to installation completion. The installation teams were praised for working safely, effectively, and maintaining schedule adherence.
The successful implementation reflects Kardex's expertise in developing tailored automation solutions that address specific operational challenges. By understanding ATS Group's unique requirements as a multidisciplinary technology group with diverse storage needs, Kardex delivered a solution that not only met current operational demands but also positioned the company for future growth and efficiency improvements.
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📚Related Knowledge Articles (6)
Goods-to-Person Systems
Goods-to-Person (G2P) systems revolutionize warehouse operations by bringing inventory directly to stationary picking stations, eliminating worker travel time and maximizing productivity. These automated systems combine storage, retrieval, and presentation technologies to create highly efficient picking environments.
Vertical Lift Modules (VLM)
Vertical lift modules use automated extractors to retrieve trays from vertically stacked storage positions, delivering items to ergonomic access openings for picking while maximizing vertical space utilization.
Box Conveyor Systems
Box conveyor systems transport cartons and cases through distribution centers using belt, roller, or chain conveyors optimized for the consistent dimensions and weights of boxed products.
Overhead Conveyors
Overhead conveyors suspend products from tracks mounted above the work area, freeing floor space while transporting items through manufacturing, finishing, storage, and distribution processes.
Pallet Conveyors
Pallet conveyors transport palletized loads through warehouses and manufacturing facilities using powered rollers, chains, or belts, enabling automated material flow between storage, production, and shipping areas.
Small Load Conveyors
Small load conveyors transport individual items, totes, cartons, and packages through warehouses and distribution centers using belt, roller, or slat systems optimized for lightweight products.
