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Make better use of existing space. Bring about noticeable improvements to processes.

Modernise your Warehouse with the Hi280 Shelving System and Work Assist Vehicle

This case study demonstrates how the precise adaptation of an Hi280 shelving unit to the existing room height and warehouse dimensions enabled an efficient modernisation of the existing facility.

In combination with a Work Assist Vehicle, a solution was created that makes optimal use of existing structures and significantly improves manual order-picking processes.

Project Overview

Location: Germany
Industry: Aerospace
Application: Manual order picking of sensitive and heavy products (Aircraft colours)
Initial situation: Existing warehouse with limited ceiling height
Solution: Space-adapted Hi280 shelving system combined with a Work Assist Vehicle
Objective: Efficiency improvement through modernisation of the existing warehouse

Initial Situation

The existing warehouse was clearly limited in both footprint and height. Structural expansion or the installation of a mezzanine floor was not an option. At the same time, sensitive products had to be stored safely and picked on a regular basis.

The existing manual picking process was functional, but involved unnecessary walking distances and limited ergonomic conditions. The available ceiling height was not fully utilised.

The Challenge

The objective was to develop a solution that would enhance the existing warehouse without interfering with the building structure or adding unnecessary complexity to the processes.

  • Optimal use of the available ceiling height
  • Ergonomic working conditions on all storage levels
  • Improved person-to-goods process
  • Implementation within the existing warehouse without new construction

The Solution

At the centre of the modernisation is an Hi280 shelving system precisely adapted to the actual dimensions of the storage area. Shelf height, compartment layout and aisle widths were engineered specifically to make the best possible use of the available height.

The shelving system is complemented by a Work Assist Vehicle with a height-adjustable work platform, enabling ergonomic access to all storage levels and making the full height operationally usable.

The Interaction Between Shelving and Work Assist Vehicle

The Hi280 shelving system provides the static structure of the solution. The Work Assist Vehicle acts as the operational enabler.

Products are picked directly from the shelving system, handled at an ergonomic working height and transported to the handover point. No additional handling or auxiliary equipment is required.

Results of the Modernisation

  • Improved utilisation of the available ceiling height
  • Significantly more ergonomic working processes
  • Shorter picking distances
  • Reduced additional handling
  • High acceptance in day-to-day operations

The achieved impact is based on precise engineering, not on technical complexity.

Scalability and Transferability

The concept is modular and transferable to other existing warehouses. The key factor is adapting the shelving system to the actual building conditions and complementing it with a Work Assist Vehicle where appropriate.

A suitable solution for companies looking to modernise their warehouses without constructing new buildings.

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FAQ

Applications, variants and expansion options

Questions that arise when transferring this solution to other applications

Can this solution be used in other industries?

Yes. The combination of shelving systems and vehicle‑assisted picking is suitable for many industries that rely on manual or semi‑automated small‑parts storage. Typical applications include industrial manufacturing, spare parts logistics, maintenance operations, automotive supply and retail environments. The system layout is always adapted to the specific project requirements.

Can other items be stored instead of paint containers?

Yes. The shelving system is designed for a wide range of stored goods, such as bins, cartons, components or spare parts. Shelf types, spacing and safety elements can be configured to match the characteristics of the stored items.

Are different weights and item dimensions possible?

Yes. Shelf loads, widths and depths can be configured according to the required capacities. The system is engineered based on the actual weights and dimensions of the stored goods and in compliance with applicable standards and guidelines.

Is the solution suitable for changing product assortments?

Yes. Shelving systems are modular by design and can be reconfigured or expanded if product ranges, quantities or processes change over time. This allows a high degree of flexibility for future adaptations.

Can other robotic solutions be used instead of a Work Assist Vehicle?

In principle, yes. Depending on throughput requirements, process design and automation level, the shelving system can also be combined with alternative automated or semi‑automated solutions. Technical feasibility is assessed on a project‑specific basis.

Is it possible to add automation at a later stage?

Yes. Many projects start with manual processes and are later upgraded step by step. The shelving layout can be planned in a way that allows future automation or the integration of robotic solutions.

Does the solution meet safety and compliance requirements?

Yes. System design, installation and operation are carried out in accordance with applicable standards and regulations. Safety, load capacity and ergonomic requirements are taken into account during project planning.