Industry
Mechanical engineering and metalworking
AutomationWare: SILO² and MAXIᴸ for industrial robotics, directly feeding the assembly line
- Mechanical and metallurgic
- MAXI L
- SILO²
- Accessosries and components
- Long items
Just-in-time in robotics: the right materials at the picking and refilling station exactly when the line needs them
At the new Maerne di Martellago facility, designed according to Lean Manufacturing and Smart Factory principles, AutomationWare processes 7 to 8 production orders every day, each made up of 40 to 50 item codes, for around 500 warehouse in/out operations. In a just-in-time production environment where every delay has a direct impact on the assembly line, component and material management must be accurate, fast and fully synchronized with the production flow.
ICAM installed two complementary systems in direct service to the line: SILO² for components, gearboxes, motors and small parts, and MAXIᴸ for aluminum bars and profiles, replacing fixed shelving and traditional racks.
Products
SILO²
MAXIᴸ
Key results
· material access times drastically reduced
· full real-time traceability
· improved operator ergonomics and material protection
Key feature
Two complementary systems for line-side supply, integrated with the ERP
AutomationWare: electric actuators and collaborative robotics for global markets
Founded in 2002 in Maerne di Martellago, near Venice, AutomationWare designs and manufactures linear and rotary electric actuators, mechatronic systems and collaborative robotics solutions for Pick&Place applications based on ROS, Robot Operating System. It serves industrial packaging, medical and pharmaceutical automation, energy production, and metal and plastic processing, with a distribution network across Europe, Asia and the United States.
The new 5,000 m² facility, designed entirely around Lean Manufacturing and Smart Factory principles, was built to eliminate every form of waste in the production flow and support double-digit growth in international markets.
The new 5,000 m² facility, designed entirely around Lean Manufacturing and Smart Factory principles, was built to eliminate every form of waste in the production flow and support double-digit growth in international markets.
The logistical challenges
With 7 to 8 production orders per day, each made up of 40 to 50 item codes, and around 500 warehouse in/out operations, material management had become a bottleneck for the assembly line.
The main critical issues were:
- Slow manual search on fixed shelving and traditional racks: locating storage positions and checking the picked material took time away from production
- No real-time visibility over stock levels: risk of stockouts on critical components, with a direct impact on delivery times
- Manual handling of aluminum bars and profiles: physically demanding and higher-risk operations on heavy, bulky materials, with no ergonomic support
- Production floor space taken up by shelving and racks, while the available height remained unused
- No integration between warehouse and ERP: replenishment based on manual estimates and unreliable inventory data
SILO² in the assembly area: components and small parts delivered to the picking and refilling station with no waiting time
The SILO² multi-column Vertical Lift Module is installed directly in the assembly area, with 3 storage columns, 2 side-by-side picking and refilling stations and a 23.21 m² footprint for 27.15 m³ of capacity.
The picking and refilling stations serve both operators in manual mode and a cobot on an AMR, which autonomously identifies the components to pick or refill and operates at the station without human intervention.
The two side-by-side picking and refilling stations ensure operational continuity: while an operator or the cobot completes a pick at one station, the storage system is already preparing the next tray at the other, eliminating waiting time between one mission and the next.
The picking and refilling stations serve both operators in manual mode and a cobot on an AMR, which autonomously identifies the components to pick or refill and operates at the station without human intervention.
The two side-by-side picking and refilling stations ensure operational continuity: while an operator or the cobot completes a pick at one station, the storage system is already preparing the next tray at the other, eliminating waiting time between one mission and the next.
ICON integrated with ERP: real-time stock levels and delivery within four weeks from order
ICON, ICAM’s automated warehouse management software, is integrated with the company ERP: every movement automatically updates stock levels, providing real-time visibility over all stored components.
Replenishment is planned based on actual consumption, eliminating manual estimates and the risk of stockouts on critical components. Inventory is available in just a few clicks.
The adoption of the just-in-time method, together with ICAM automated storage systems, has enabled AutomationWare to guarantee delivery within four weeks from customer order.
Replenishment is planned based on actual consumption, eliminating manual estimates and the risk of stockouts on critical components. Inventory is available in just a few clicks.
The adoption of the just-in-time method, together with ICAM automated storage systems, has enabled AutomationWare to guarantee delivery within four weeks from customer order.
MAXIᴸ: aluminium bars and profiles handled safely, 31 drawers with a load capacity of up to 1,000 kg
The MAXIᴸ automated vertical storage system is installed in direct service to the assembly line for the management of aluminum bars and profiles up to 6.5 meters long, with load capacity up to 1,000 kg per drawer, replacing traditional racks.
When a production order is launched, the system delivers the correct drawer to the load/unload station, with no manual search required: profiles arrive at ergonomic height exactly when the line needs them, eliminating manual handling of heavy and bulky materials.
ICON and the company ERP integration provides real-time visibility over stock levels, with replenishment planning based on actual production consumption.
When a production order is launched, the system delivers the correct drawer to the load/unload station, with no manual search required: profiles arrive at ergonomic height exactly when the line needs them, eliminating manual handling of heavy and bulky materials.
ICON and the company ERP integration provides real-time visibility over stock levels, with replenishment planning based on actual production consumption.
Key results
Assembly line always supplied, delivery within 4 weeks, no waiting time, no stockouts
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Delivery within 4 weeks from order
Just-in-time production, enabled by automation, made it possible to establish and reliably meet a defined lead time for every production order
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500 daily in/out operations with no bottlenecks
Continuous flow across 7 to 8 daily production orders, each made up of 40 to 50 item codes, managed in direct line-side supply
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Material access times drastically reduced
manual search, location identification and verification procedures eliminated: components arrive exactly when the line needs them
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Cobot on AMR integrated into the flow
the autonomous robot operates at the SILO² picking and refilling station without human intervention, extending operational capacity without increasing headcount
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Stockouts eliminated
ICON–ERP integration with stock levels always up to date, replenishment planned on actual consumption, and inventory available in just a few clicks
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Production floor space recovered
The vertical layout of both systems frees up floor space for production
To keep pace with our customers’ high expectations, the investment in our new facility and the automation of our internal logistics processes with ICAM’s automated warehouses will allow us to increase productivity, reduce delivery lead times and strengthen our supply chain for the long term.
Discover the solutions chosen by AutomationWare
SILO²: the Vertical Lift Module
With 2 to 7 storage columns, over 120 tray size configurations and specific tray 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.
Explore SILO²
MAXIᴸ : the vertical storage system for long materials
Automated vertical storage system for bars, tubes, profiles and semi-finished materials, with drawers offering load capacity up to 3,000 kg, height-expandable structure, indoor or outdoor installation, and motorized shuttle with access configurable on all four sides.
Explore MAXI L
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