Industry
Military and aviation
Benelli Armi: cobots and SILO² for automated picking and kitting
- Military & aviation
- SILO²
- Accessosries and components
- Pallet
A robotic cell for just-in-time supply to the assembly lines
To automate production kit preparation, reduce kitting errors and free operators from repetitive and high-risk tasks, Benelli Armi integrated 3 collaborative robots, or cobots, with ICAM’s SILO² multi-column Vertical Lift Module at its Urbino facility.
The result is a fully automated robotic picking and kitting cell, operating 24 hours a day without supervision, which eliminated kit assembly errors and freed up over 80 m² of floor space.
Product
SILO²
Key results
· 80 m² of floor space freed up
· kit assembly errors eliminated
· just-in-time supply to the assembly lines
Key feature
Robotic cell with 3 cobots integrated with SILO²
Benelli Armi: a global leader in semi-automatic shotguns
Founded in 1967 in Urbino, Benelli Armi is a global leader in the production of semi-automatic shotguns for hunting, sport shooting and defense applications, with a 20% share of the global market and a presence in 78 countries. Part of Beretta Holding since 1983, the company designs and manufactures its entire semi-automatic range in-house, according to extremely high quality standards.
The complexity of the production process, with hundreds of small, strategically important components that must flow in a synchronized way to the assembly stations, made internal logistics a critical factor for production continuity and quality.
The complexity of the production process, with hundreds of small, strategically important components that must flow in a synchronized way to the assembly stations, made internal logistics a critical factor for production continuity and quality.
The logistical challenges
Although small in size, the components used in production kits have high strategic value: if they are not available, production slows down or stops.
In 2016, Benelli launched a project to fully automate the preparation, storage and just-in-time picking of assembly kits for production.
The existing storage and kitting process presented significant challenges:
Around 100 m² of floor space occupied by static racking with a traditional pick-to-light system.
Two operators across two shifts required to walk long distances and use ladders, with a real risk of injury.
Frequent errors in kit assembly, with a direct impact on workstation operations.
Components exposed to dust, humidity and UV rays, as well as potential unauthorized access.
Racking no longer suitable for the growing number of SKUs.
SILO² and 3 cobots: automated 24/7 picking and kitting in 12 m²
The project led to the installation of a robotic cell: 3 cobots interfaced with a SILO² multi-column Vertical Lift Module with 2 storage columns and 2 side-by-side picking and refilling stations. The storage system is 6 meters high and provides 18 m³ of capacity in just 12 m², freeing up over 80 m² compared with the previous racking setup.
One picking and refilling station is dedicated to the cobots: equipped with 3D vision, they pick loose components from the tray and assemble the kits in the corresponding boxes, passing parts between robotic arms to optimize cycle times. The other station is reserved for operators, who replenish components and distribute completed kits to the production lines.
One picking and refilling station is dedicated to the cobots: equipped with 3D vision, they pick loose components from the tray and assemble the kits in the corresponding boxes, passing parts between robotic arms to optimize cycle times. The other station is reserved for operators, who replenish components and distribute completed kits to the production lines.
ICON and ERP integration: automatic orders, stock updated in real time
Orders arrive from the company ERP, are checked against SILO² stock levels via ICON and are automatically sent to the cobot control system.
Every operation updates stock in real time. The cobots operate unmanned 24/7, ensuring production continuity and consistent accuracy with no human intervention required in the picking and kitting cycle.
Every operation updates stock in real time. The cobots operate unmanned 24/7, ensuring production continuity and consistent accuracy with no human intervention required in the picking and kitting cycle.
Key results
Operational excellence 4.0: precision, safety and continuous productivity
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Automated kitting 24/7
the cobots operate without supervision, even outside working hours
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Kit assembly errors eliminated
the cobots’ 3D vision system eliminates manual picking and kitting errors
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–80 m² of floor space
from around 100 m² of traditional racking to a 12 m² automated storage and robotic system
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Just-in-time line-side supply
kits reach the assembly stations at the right time, in the right quantity
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Repetitive, low-value tasks eliminated
freed from walking distances and ladder use, operators can now focus on higher-value activities
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Components protected and tracked
stored in an enclosed environment, protected from dust, humidity, UV exposure and unauthorized access, with movements updated in real time
In precision manufacturing, a missing or incorrect kit is not an inconvenience: it means line downtime.
With the integration of cobots and SILO² VLM, Benelli Armi transformed one of the plant’s most critical logistics bottlenecks into an autonomous, accurate and continuous system, operating 24/7, error-free and in less space than before.
Discover the products chosen by Benelli Armi
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
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