Auto Parts Supplier Meat&Doria Automates Warehouse

About Meat&Doria

Meat&Doria, a key player in the automotive aftermarket industry, operates globally from its base in Trofarello, Italy. As part of the M&D Group, it specializes in electrical and electronic components, contending with increasing market demands and logistical complexities that are common across the industry. The recent years have seen significant shifts in logistics practices, influenced by growing inventory levels and the push-pull of market dynamics.

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"In recent years, the trend of increasing inventory levels has strongly influenced modern logistics. Indeed, regardless of the industry, almost all manufacturers and distributors are tasked with managing scenarios that poorly align with the goal of minimizing inventory. On one hand, the recent pandemic has caused significant delays and uncertainties in global supply chains, increasing costs and forcing companies to elevate inventory levels to ensure service continuity and protect their business. On the other hand, there is an intensifying tendency downstream in the distribution chain to minimize stock to reduce warehouse expenses, while increasing order frequency to ensure maximum coverage of user needs," explains Marco Lacastellana, COO of Meat&Doria.

"Our regional distributor, our first and main contact, cannot invest in the entire range but must respond to any customer request. This dynamic results in an ever-increasing number of shipments, many of which are urgent," Marco Lacastellana adds.

Challenges in Traditional Warehouse Management

Before implementing AutoStore, Meat&Doria grappled with the above-mentioned challenges of managing a vast and slow-moving inventory that strained their traditional warehouse setup. The company faced high operational costs and inefficiencies, including excessive stock levels and protracted order processing times. Limited storage capacity and outdated manual processes further hindered their ability to adapt to rapidly evolving market demands.

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AutoStore Solution

In response to these challenges, Meat&Doria implemented the AutoStore system, empowered by Swisslog, designed to maximize space utilization and streamline operations. The system featured 25 R5 Robots and over 16,000 Bins within a compact 560 square meter (6,028 square feet) area, drastically reducing the need for manual handling and enabling quick access to inventory.

Marco Lacastellana on the Decision for AutoStore

"In order to increase productivity and storage capacity, we considered several solutions such as vertical warehouses and Miniload and Maxi-shuttle systems. However, the business growth forecasts for the next five years left no doubt: AutoStore seemed to us from the start as the only option capable of guaranteeing scalability, modularity, and robust evolution," Marco Lacastellana confirms.

How the System Works

The AutoStore system operates on a 'goods to person' principle, where Robots retrieve Bins and deliver them to operators at picking stations. This setup integrates seamlessly with Meat&Doria’s Warehouse Management System, enhancing the flow of goods from receipt to dispatch and significantly boosting operational efficiency.

Operational Efficiency and Strategic Advantages

Since implementing AutoStore, Meat&Doria has achieved a 190% increase in order picking efficiency, managing about 5,000 order lines daily with enhanced accuracy and speed. The system’s scalability has allowed for continuous growth in inventory without expanding the warehouse footprint, reflecting substantial cost savings and better resource utilization.

Marco Lacastellana on Operational Efficiency

"For us, a fundamental KPI is the customer service level, understood as order fulfillment. We could perform 40 lines/hour with manual picking. With AutoStore, we can now reach 130 lines/hour for each of the four picking stations, potentially expandable to six. The significant increase in productivity helps us manage the growing number of orders and the increasingly frequent urgencies," Marco Lacastellana confirms.

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System Overview

Installation type: Brownfield (Existing site)
WMS: Incas SSI SCHÄFER
Robots: 25 R5 Robots
Bins: 16,000
Workstations (Ports): 4 CarouselPorts, 4 ConveyorPorts
Partner: Swisslog