Dafram Automates PPE and Consumables Distribution with SafeBox: 24/7 Self-Service and 100 m² Reclaimed

Materials and tools always available, with no waiting, including on the night shift

As order volumes increased and a third shift was introduced, the internal distribution of PPE, tools and consumables became a bottleneck. Dispensers were scattered across the facility, operators spent too much time moving between locations, and materials already in stock were often repurchased at the last minute.
To streamline access and improve inventory control, Dafram installed ICAM SafeBox at the center of the facility. The system provides a single self-service distribution point available across all shifts, with badge-based access for each operator and ERP integration for real-time consumption monitoring.

Industry

Mechanical engineering and metalworking

Product

SafeBox

Key result

– 100 m² of floor space recovered
– 5,000 SKUs in 20 m²
– 24/7 self-service PPE distribution

Key feature

SLOT system for role- and task-based access control

Dafram: vertically integrated manufacturing for the Oil & Gas sector

Founded in 1956 in Urbisaglia, Italy, Dafram is a leading manufacturer of ball valves for the Oil & Gas industry, serving major EPC contractors and some of the world’s leading energy companies.
All production processes are managed in-house at a 32,000 m² facility. Operations include foundry, machining with multi-axis machining centres and CNC lathes, welding, sandblasting, painting and specialised testing. The company manufactures ball valves ranging from ½ to 56 inches, including custom configurations delivered to customer specifications and lead times.

The logistical challenges

Growing order volumes led to the introduction of a third shift, making it essential to ensure continuous access to PPE and consumables during night-time operations without dedicated personnel.

Manual management created operational inefficiencies and often resulted in urgent purchases of materials already available on site, an avoidable cost that called for a more structured approach.

The main challenges of the previous distribution system were:

Materials stored across shelving and small dispensing units located throughout the facility.
Frequent operator travel during shifts to retrieve required items.
Time-consuming search and picking activities.
Limited visibility of inventory levels.

SafeBox at the heart of facility: 5,000 SKUs in 20 m², 24/7 access

SafeBox is installed at the centre of Dafram’s facility to provide fast access from every department across all shifts. Standing 3.5 metres high and 8 metres wide, it stores more than 5,000 SKUs in just 20 m². PPE, tools, consumables for machining operations and measuring instruments are organised in 214 custom-configured containers.
Each operator can access the system independently using a company badge or personal credentials, without requiring assistance from a supervisor.

SLOT and ERP-integrated ICON: role-based access to materials

The SLOT system manages selective distribution: each operator can only pick the items linked to their profile, based on their role and the task to be performed, eliminating waste and unauthorized access. The slots can be configured in different sizes, from compact compartments for small parts and inserts to wider bins for PPE kits, workwear or heavy tools. This allows operators to pick items in a single operation, even when the same items would require multiple transactions in a traditional vending machine. If needed, operators can request extra material directly at the storage system.
ICON Safe, an ICON module developed for controlled item distribution, is integrated with the company ERP system. It enables real-time inventory monitoring, consumption-based replenishment planning, and certified tracking of every PPE withdrawal in compliance with Italian Legislative Decree requirements. 81/08.

Key results

More efficient, controlled and always-available materials distribution

Over 100 m² of space recovered

traditional racking and scattered dispensers removed, freeing up valuable production space.
5,000 SKUs in 20 m²

PPE, tools, consumables and measuring instruments are centralised in a single access point available to all departments.
Continuous operation across three shifts

operators can independently pick materials via badge access, even during night shifts, without dedicated on-site supervision
Operator autonomy

role-based self-service eliminates operational interruptions for supervisors and frees up time for higher value-added activities.
Monitored consumption and planned replenishment

ICON Safe, integrated with the ERP system, provides real-time inventory visibility and eliminates urgent purchases of materials already available on site.
Certified PPE withdrawals

every operation is digitally recorded, ensuring compliance with Italian Legislative Decree 81/08 without the need for manual documentation.

With SafeBox we have reclaimed space within the facility and simplified materials management. Today every operator is autonomous when collecting PPE and tools, without burdening supervisors — with a direct impact on operational efficiency.

Fabio Lambertucci Production Manager, Dafram