The solution – a Vidir single-tower sheet metal vertical lift system (VLS) – delivered measurable results in days, providing a rapid return on investment and continuing to generate savings year after year.
The Challenge: Heavy Sheets, High Risks, and Lost Time
Before automation, this facility stored sheet metal bundles weighing up to 5,000 lbs. on static cantilever racks. Every pick required a certified forklift operator and a second employee to assist. A single retrieval took around six minutes…time that multiplied quickly in a 24/7 operation.
Beyond the productivity loss, safety was a constant concern. Lifting thousands of pounds 16 feet in the air meant that one wrong move could damage expensive material – or worse, cause injury. Every pick required a spotter. Forklift congestion slowed production flow, and operators often discovered unused sheet metal hiding in the racks, driving unnecessary reorders.
The Solution: A Safer, Faster, Smarter Storage System
The facility installed a single-tower sheet metal VLS, which stores heavy sheet metal bundles vertically within a fully enclosed system. With the push of a button, the system automatically retrieves the correct bundle and delivers it to ground level for safe, one-person access.
Key advantages:
- No forklift required – any trained employee can retrieve materials.
- Single-operator picking – no spotter needed.
- Improved floor space – vertical design freed up space for revenue-generating equipment.
- Reduced material damage – fully contained storage minimizes handling risks.
- Better inventory control – operators can see what’s in stock at a glance.
The Results: Efficiency That Adds Up
The impact was immediate:
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- 34+ labor hours saved per day
- Retrieval time cut from 6 minutes to under 60 seconds
- With the reclaimed floor space, the manufacturer set up a new manufacturing line for valves and fittings
- One employee per pick instead of two
- Bonus: no forklift certification required
Their biggest a-ha moment? The difference in picking speed was a game-changer – and they were able to eliminate the spotter from sheet metal retrieval. It was a win-win: the increase in picking speed made them more productive, and the reduction in staffing saved them money.
Annual savings:
- $212,784 in labor costs
- $15,950 in reclaimed floor space
- $228,734 in total yearly savings
With more than $228,000 in annual savings, the system delivered a rapid ROI and continues to provide long-term value through safer operations, greater efficiency, and better use of space.
Looking Ahead: Scaling with Dual-Tower Capacity
This customer’s success demonstrates what’s possible with automation, and it’s just the beginning. For operations with higher volumes or more SKUs, installing a dual-tower sheet metal VLS doubles capacity while maximizing footprint efficiency, unlocking even more savings and throughput potential.
See how a Vidir sheet metal VLS can transform your facility.
