Industry
Electric
Electric Line: ICAM automated storage systems integrated with ERP for Industry 4.0 intralogistics
- Electric
- COMPATTA
- SILO²
- Accessosries and components
Four automated storage systems working as one for more than 25,000 SKUs
To manage an inventory of 15,000 raw material SKUs and 10,000 finished product SKUs, ranging from electronic components to cable reels, Electric Line automated the intralogistics operations at its Pontirolo Nuovo facility with ICAM automated storage systems integrated with the company ERP: three SILO² VLMs and a COMPATTA mobile racking system.
Each system addresses a specific storage requirement. Together, they create a fully digital and fully traceable material flow.
Products
3 SILO² vertical lift modules
1 COMPATTA mobile racking system
Key results
• 3,000 SKUs in 50 m²
• Centralised storage for 1,000 mini-applicators
• Double storage capacity for heavy loads
Key features
• ICON–ERP integration
• Multi-application flexibility
Electric Line: made-to-order cable assemblies for demanding sectors
Founded in 1992 near Bergamo (Italy), Electric Line specialises in the design, production and distribution of customised electrical and industrial wiring systems, gearmotors and electric motors for demanding industries, including Ho.Re.Ca., medical devices, industrial automation, automotive and rail.
UL-certified for exports to the United States and Canada, the company manages every stage of the process in-house, from prototyping to testing, at its 13,000 m² facility, supported by a production site in Slovakia dedicated to cable assembly.
Highly customised projects, more than 25,000 SKUs and a wide variety of materials differing in size, weight and handling requirements had turned manual warehouse management into a growing operational constraint.
UL-certified for exports to the United States and Canada, the company manages every stage of the process in-house, from prototyping to testing, at its 13,000 m² facility, supported by a production site in Slovakia dedicated to cable assembly.
Highly customised projects, more than 25,000 SKUs and a wide variety of materials differing in size, weight and handling requirements had turned manual warehouse management into a growing operational constraint.
The logistical challenges
Following the relocation to its new facility, Electric Line needed to completely redesign its warehouse processes.
Different needs required different solutions: not a single system, but an integrated ecosystem.
The main challenges were:
• 15,000 raw material item codes and 10,000 finished goods item codes managed on static racking using paper documents and Excel spreadsheets
• heterogeneous SKUs (connectors, cables, terminals, reels and gearmotors) managed without a storage system differentiated by product type
• long picking times, with operators forced to search for items on shelving and use ladders to access upper levels
• lack of traceability, leading to picking errors and a direct impact on lead times
• small applicators used in the cutting department scattered across different shelves, causing confusion and time loss during machine setup
2 SILO² VLMs for kit preparation: over 3,000 SKUs in just 50 sqm
The 2 side-by-side SILO² VLMs, each approximately 10 metres high with 3 storage columns and 2 picking/refilling stations equipped with IRIDE, manage more than 3,000 component SKUs in less than 50 sqm overall. SKUs are evenly distributed between the two systems to ensure operational backup and allow 3 operators to work in parallel.
Storage allocation follows combined usage frequency: components commonly picked together are stored together to form kits. Orders received by email automatically generate work orders with picking lists displayed directly on the workstation PC. An average 25-item picking list is processed in approximately 30 minutes: each SILO² manages around 70 picking operations and 25 refilling operations daily.
ICON-ERP integration delivers real-time stock visibility, low-stock alerts and automated FIFO.
Storage allocation follows combined usage frequency: components commonly picked together are stored together to form kits. Orders received by email automatically generate work orders with picking lists displayed directly on the workstation PC. An average 25-item picking list is processed in approximately 30 minutes: each SILO² manages around 70 picking operations and 25 refilling operations daily.
ICON-ERP integration delivers real-time stock visibility, low-stock alerts and automated FIFO.
SILO²: fast, controlled tool management in the cutting department
In the cutting department, the application tools required for CNC machining, cable cutting, stripping, crimping and tinning operations were stored across multiple shelving locations, making machine setup slower and less efficient.
The 5.5-metre-high SILO² VLM occupies just 5.15 m² while centralising approximately 1,000 application tools across 37 trays.
The department manager is the sole authorised user: each day they remotely load the following day’s movement plan so colleagues get exactly the right applicator for the job in hand. Around 10 picks and 5 refilling operations per day.
The 5.5-metre-high SILO² VLM occupies just 5.15 m² while centralising approximately 1,000 application tools across 37 trays.
The department manager is the sole authorised user: each day they remotely load the following day’s movement plan so colleagues get exactly the right applicator for the job in hand. Around 10 picks and 5 refilling operations per day.
COMPATTA: double storage capacity for heavy and bulky item
For cable reels, gearmotors, pallets, and bulky items, Electric Line has installed a COMPATTA system featuring five 19.5-meter-long mobile units and a four-tier pallet rack that is 5 meters high. The system runs on floor rails and creates an aisle only where needed; it can also be opened via remote control from the forklift.
The system manages approximately 2,500 SKUs, handling around 50 picking operations and 30 refilling operations per day. Orders typically consist of around 10 SKUs and are completed in approximately 10 minutes.
Compared to the previous static racking system, COMPATTA doubled storage capacity without increasing the footprint.
The system manages approximately 2,500 SKUs, handling around 50 picking operations and 30 refilling operations per day. Orders typically consist of around 10 SKUs and are completed in approximately 10 minutes.
Compared to the previous static racking system, COMPATTA doubled storage capacity without increasing the footprint.
Key results
An integrated logistics ecosystem built for made-to-order complexity
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3,000 SKUs in 50 m²
The 2 SILO² VLMs consolidate small components with IRIDE-guided kit picking
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Storage capacity doubled
COMPATTA manages 2,500 heavy and bulky SKUs in the same space as the previous racking system
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1,000 applicator tools centralised
SILO² eliminates scattered storage and reduces setup time in the cutting department
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Full traceability
Every movement logged in real time via ICON-ERP integration across all three systems
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Automated FIFO
Stock obsolescence eliminated across all flows
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Optimised kit picking
Joint-frequency allocation cuts fulfilment time on the most complex pick lists
The cornerstone of Electric Line has always been our vast assortment of products and our speed of delivery. ICAM automated storage systems have helped us to optimize the handling of a growing number of items that we have added to our collection over the years. In this way we can continue to offer customers the same excellent level of service that has always characterized Electric Line, both in terms of quality and lead times.
Discover the products chosen by Electric Line
SILO²: the Vertical Lift Module
With 2 to 7 storage columns, over 120 tray size configurations and specific load bearing capacity up to 1,000 kg/m², SILO² is ICAM’s answer for companies managing small and medium-sized items, even those with a very high specific weight, in high-intensity operational environments. Fast picking, tracked operations and recovered space. All coordinated by ICON, ICAM’s proprietary software
Explore SILO²
COMPATTA: the Mobile Racking System
Motorized mobile racking bases compatible with any existing racking type. COMPATTA handles the heaviest and most demanding loads, operates in environments down to -30°C, and is the solution for operations that need to maximize storage density without sacrificing configuration flexibility.
Explore COMPATTA
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