Modula Vertical Lift Modules: How Automated Vertical Storage Can Benefit Your Business 

How Does a Modula Vertical Lift Work?

These Vertical Lift Modules (VLMs) make it easy for large amounts of inventory to be stored and easily accessible while being stored in a secure, clean environment. The easy-to-use design that feautres a user friendly control system allows for increased productivity and decreased picking errors. 

The Modula VLMs thrives on the high ceilings that most warehouse facilities have. When floor space is a premium, why not go up? FORCE America currently has three Modula Vertical Lift Modules (VLMs) in our Savage, MN warehouse. With our 24’ ceiling height, each Modula Vertical Lift holds about 75 drawers. The great thing about the Modula Vertical Lift is that they are customizable to the height of your ceiling.

These lifts work in a few simple steps

1. An order barcode is scanned at a central computer that controls the three Modula Vertical Lifts
2. The computer software looks for parts in all three machines at one time
3. Each machine then starts sending products down to the operator

Our Modula Vertical Lifts have a two-drawer delivery system. This improves pick times because once the drawer is moved into position for item removal, the Modula will bring down another drawer. 

After the inventory is removed from the drawer, the operator pushes a button on the Copilot Console or the Put-to-Light Bar. This tells the Modula that the parts are out of the drawer and its ready to go back in the rack. Once the drawer is put back, Modula will find the next drawer that has inventory for that order. This process repeats until all items for that order have been removed. Another great feature of this system is that multiple orders can be picked at a time. The Modula software can organize inventory from multiple orders.

Our Modula Vertical Lifts also contain the Alphanumeric display bar and the laser pointing system. The alphanumeric display shows what item is in the drawer and the quantity to be removed. The laser pointing system produces a green dot in the compartment of the component meant to be picked. The copilot console also highlights the compartment that contains the part. These systems are designed to help the operator ensure picking accuracy. Picked components are then placed on carts based on the order they come from. The operator then goes back to the Modula Vertical Lift and continues picking until the order is complete. While an operator is picking another operator could scan in other orders and the system will begin picking those orders as well.

Modula Vertical Lift Return on Investment (ROI)

With any large investment in warehouse equipment, we should calculate the length of the Return on Investment or ROI. Modula claims that depending on the size of the project, the ROI ranges from six to 18 months. With any large capital investment, it’s a good idea to calculate your own ROI but this will at least give you a general idea. There are many factors that you should consider when doing this calculation including:

1. Space savings
2. Increased Efficiency
3. Pick Rate Accuracy
4. Productivity Improvement

Space Savings

The Modula Vertical Lift Modules occupy 90% less floor space than traditional shelving. With the rising cost of warehouse rent, this space savings companies can avoid relocating to larger facilities. Staying in smaller facilities means less money spent in operating costs of that space. The extra unused space can also be used to generate profit like setting up new production lines or expanding assembly spaces. Space savings was a driving factor for FORCE America when we were looking to invest in the Modula Vertical Lifts.

Increased Efficiency

The Modula Vertical Lifts operate on a concept called goods-to-person. This means that the inventory is brought to where the operator is instead of the operator going to the inventory. This principle can improve the throughput of orders by up to 300%. Operators no longer need to go ‘UP’ to retrieve goods, the Modula Vertical Lifts bring the goods to the operator on the ground level. The operator also saves time by not having to walk great distances retrieving all the inventory on an order.

Pick Rate Accuracy

Human error that leads to the delivery of incorrect product is very costly. The extra delivery costs, man hours to repick an order and customer dissatisfaction could cost your company thousands of dollars a year. Modula systems are equipped with laser pointers, alphanumeric LED bars and the put-to-light systems help guide operators to the correct parts and the correct quantities. These systems are designed to help virtually eliminate sending the wrong parts to the customer.

Productivity Improvement

With the workforce tightening, it has become extremely difficult to find quality individuals to fill warehouse roles. A Modula system can increase productivity by up to 85%. This allows one operator to handle the workload of several individuals. The goods-to-person principle eliminates the physical strain of walking, bending or climbing ladders to retrieve parts. Because of the lower physical strain, costs associated with workplace injuries are reduced as inventory is brought to an ergonomic level for the operator.

The FORCE America Recommendation

FORCE America currently owns and operates five Vertical Lift Modules throughout two of our locations and will be installing 2-3 more in a new location this fall. Modula Systems have allowed us to design smaller more efficient spaces that better help us serve our customers with more accurate order fulfillment. By saving money on labor and better inventory management we can invest money in areas that help our company grow and better help our customers grow. Modula Vertical Lift Systems are becoming a cornerstone of all our distribution and manufacturing facilities.