{"id":10771,"date":"2026-07-21T14:35:06","date_gmt":"2026-07-21T14:35:06","guid":{"rendered":"https:\/\/www.icamonline.eu\/?post_type=case-study&p=10771"},"modified":"2026-07-21T14:39:10","modified_gmt":"2026-07-21T14:39:10","slug":"maggio-srl-silo%c2%b2-in-the-assembly-department-for-agricultural-machinery-25-picking-speed-zero-inventory-errors","status":"publish","type":"case-study","link":"https:\/\/www.icamonline.eu\/en\/case-studies\/maggio-srl-silo%c2%b2-in-the-assembly-department-for-agricultural-machinery-25-picking-speed-zero-inventory-errors\/","title":{"rendered":"Maggio Srl: SILO\u00b2 in the assembly department for agricultural machinery, +25% picking speed, zero inventory errors"},"content":{"rendered":"
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\n Automation at the heart of the shop floor: SILO\u00b2 alongside the assembly lines\n <\/h2>\n \n

\n To eliminate inventory discrepancies and speed up production order preparation, Maggio Srl, a southern Italian manufacturer of professional agricultural machinery for specialised crops, installed an ICAM SILO\u00b2 Vertical Lift Module directly in its assembly department, bringing picking right to the assembly lines and eliminating production stoppages caused by warehouse errors.\n <\/p>\n <\/header>\n \n

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\n Industry\n <\/h3>\n \n

\n Mechanical Engineering & Metal Processing\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n Product\n <\/h3>\n \n

\n SILO\u00b2\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n Key results \n <\/h3>\n \n

\n +25% order fulfilment speed
\r\n+50% storage capacity, same footprint
\r\n– Zero inventory errors\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n Key features\n <\/h3>\n \n

\n – Integration with INTEGRY ERP via ICON and guided picking with IRIDE
\r\n– Real-time pick and deposit validation via WMS handheld\n <\/p>\n <\/div>\n\n <\/article>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n\n\n

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\n Maggio Srl: professional agricultural machinery for specilised crops\n <\/h2>\n \n
\n Maggio Srl was founded in 1972 in Rutigliano (BA), southern Italy. The company designs and manufactures professional agricultural machinery for specialised crops (sprayers, seeders and inter-row cultivators for vineyards, orchards and greenhouses) distributed through a network of agents and dealers covering both the domestic market and international markets as far as Australia.
\r\nWith a team of 15 people operating on a single shift, Maggio manages a complete production cycle: from frame fabrication through to assembly, testing and dispatch. A lean structure where any logistical inefficiency translates directly into production delays.
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\n \"Maggio\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n\n\n
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\n The logistics challenges\n <\/h2>\n \n
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Around 2,000 critical SKUs on wall-mounted racking: nearly half the usable space inaccessible, inventory data unreliable.<\/strong><\/p>\n

Maggio\u2019s production model generates seasonal and structural logistics pressure: agricultural machines are sold and serviced at precise points in the growing cycle, and any component unavailable at the right moment translates directly into a delayed order. Speed of access to the right part is the condition that determines the reliability of the entire production operation.<\/p>\n\n <\/div>\n <\/div>\n\n

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Before automation, five structural constraints defined the operation:<\/p>\n

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  • inaccessible storage area:<\/strong> wall-mounted racking left the inner half of every shelf unreachable by hand, around half of the total storage capacity effectively wasted<\/li>\n
  • slow manual picking<\/strong>:\u00a0operators using ladders and forklifts, 40 minutes to fulfil a standard pick list of 30\u201350 SKUs<\/li>\n
  • frequent inventory discrepancies: <\/strong>mandatory pre-checks before starting every production order<\/li>\n
  • annual physical stocktake<\/strong>: 3\u20134 weeks of dedicated labour<\/li>\n
  • production stoppages from discrepancies<\/strong>: 2\u20133 days lost per incident, up to a week in the worst cases<\/li>\n
  • sensitive components exposed<\/strong>: PCBs, on-board computers and precision nozzles stored on open racking<\/li>\n<\/ul>\n

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    \n SILO\u00b2 three-column VLM in the assembly department: 38.63 m\u00b3 for over 2,000 critical SKUs in 20 m\u00b2\n <\/h2>\n \n
    \n A SILO\u00b2 Vertical Lift Module was installed directly in the assembly department, right alongside the production lines. The system is 6.1 metres in height, configured with 3 storage columns and 2 side-by-side picking and refilling stations, delivering a useful volume of 38.63 m\u00b3. This space holds over 2,000 SKUs selected from the most critical items in the catalogue (precision nozzles, valves, filters, hydraulic fittings, on-board computer components, fasteners and special hardware, bearings, gears and seal kits) out of a total of 13,000 SKUs in the warehouse, of which 5,000\u20136,000 are active. The existing racking was dismantled and the space returned to production.\n <\/div>\n \n <\/div>\n\n
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    \n \"maggio_magazzino_ricambi_macchine\"\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n\n\n
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    \n Dual allocation logic: kit-based picking\n <\/h2>\n \n
    \n Unlike fixed racking where each shelf level was dedicated to a single machine model, items in the SILO\u00b2 follow a dual allocation logic: product category and destination machine. Components for sprayers, seeders and cultivators are grouped on the same tray or on adjacent trays. When a pick list arrives, the VLM delivers the materials to the station already grouped by production order: an average of 3\u20135 items are picked per tray movement, with no travel and no manual searching.\n <\/div>\n \n <\/div>\n\n
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    \n \"Dual\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n\n\n
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    \n ICON\u2013INTEGRY integration and guided picking with IRIDE\n <\/h2>\n \n
    \n The SILO\u00b2 is integrated with the INTEGRY production ERP through ICON, ICAM\u2019s warehouse management software. Pick lists originate in INTEGRY and are imported into ICON; the VLM sequences the trays accordingly and the operator finds the material already positioned at the station, guided by IRIDE, ICAM\u2019s smart picking device, which indicates the exact SKU code and quantity to pick. Every movement is confirmed via WMS handheld in real time. Replenishment is scheduled during lower-demand periods; critical operations (stock loading, new SKU coding, bulk picks) are restricted to warehouse supervisors.\n <\/div>\n \n <\/div>\n\n
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    \n \"ICON\u2013INTEGRY\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n\n\n
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    \n Key results
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    \n More speed, more space, more control: production that never stops.\n <\/p>\n <\/header>\n \n

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      \n +50% storage capacity, same footprint\n <\/h3>\n \n

      \n The racking occupied the same floor area as the SILO\u00b2 VLM, but around half of every shelf bay was unreachable. The vertical system uses the full available height: no dead zones, no inaccessible racking.\n <\/p>\n <\/div>\n <\/li>\n \n

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      \n +25% order fulfilment speed\n <\/h3>\n \n

      \n From over 40 to about 30 minutes for a standard pick list of 30\u201350 SKUs\n <\/p>\n <\/div>\n <\/li>\n \n

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      \n Zero inventory errors\n <\/h3>\n \n

      \n Across 2,000 SKUs managed in the SILO\u00b2, ICON and INTEGRY sync in real time. Physical checks have been reduced to spot controls on critical items.\n <\/p>\n <\/div>\n <\/li>\n \n

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      \n Production stoppages reduced to rare events\n <\/h3>\n \n

      \n Inventory discrepancies that previously cost 2\u20133 days of production downtime up to a week in the worst cases are now rare occurrences.\n <\/p>\n <\/div>\n <\/li>\n \n

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      \n +4x throughput at seasonal peaks\n <\/h3>\n \n

      \n At peak the system handles up to 800\u2013900 movements per day, four times a standard day\u2019s volume: production keeps running even when the agricultural season accelerates.\n <\/p>\n <\/div>\n <\/li>\n \n

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      \n Full movement traceability\n <\/h3>\n \n

      \n Every pick logs operator, timestamp and production order. No blind spots between production, warehouse and aftersales.\n <\/p>\n <\/div>\n <\/li>\n <\/ul>\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n\n\n

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      \n With the SILO\u00b2 we finally have a warehouse that works the way we do: by order, by machine, with no time wasted searching. Knowing exactly what\u2019s inside and where it is has changed the way we organise production every morning\n <\/p>\n\n