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Rubber & Plastic Products Manufacturing

First Project for a Leading TPU Film Manufacturer

Process Line-Side Warehouse

Features: Large 5-Meter Automated Storage System to Improve Material Management Efficiency; Vertical Storage Design to Reduce Floor Space Occupancy; Enclosed Storage with Access Control to Strengthen Material Control; Connected with the Factory Management System to Improve Information Synchronization Efficiency; Real-Time Material Information Updates to Reduce Inventory Discrepancies; Layered Management and Position Indication to Reduce Picking Errors; Automatic Height Detection Light Curtain to Improve Storage Location Utilization; Fast Storage and Retrieval Operations to Improve Material Issuing Efficiency

Description

This project is the first automated storage system implementation case for a leading TPU film manufacturer. The system is a large 5-meter model with a single-load capacity of 300 kg, designed for centralized material storage, fast storage and retrieval, and systematic material management.

Before the upgrade, the customer relied on conventional fixed racking for material storage. This often led to several issues, including excessive floor space usage, limited control over open storage areas, inventory discrepancies, picking errors caused by similar-looking materials, and insufficient factory space utilization.

Based on the customer’s on-site material management requirements, JY STE Technology introduced a large vertical smart storage system equipped with height detection light curtains, compartment management, position indication, ID card-based access login, and synchronization with the factory management system. The solution helps overcome the limitations of traditional warehouse management.

After implementation, materials can be centrally managed through enclosed storage and a systematic workflow. This improves space utilization and inventory accuracy while reducing manual identification errors and material picking risks. As a result, material management becomes more accurate, secure, and efficient.

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TPU FILM LINE-SIDE STORAGE CASE STUDY

TPU Film Manufacturer | Process Line-Side Warehouse
Large 5 m, 300 kg Automated Storage Case Study

This project involved the implementation of an automated process line-side warehouse for a leading TPU film manufacturer. The client previously relied on conventional fixed shelving and faced several long-term challenges, including excessive floor-space usage, uncontrolled access in an open storage environment, inventory discrepancies, picking errors caused by visually similar materials, and costly processing mistakes. JY STE designed a large 5 m, 300 kg automated storage system for the process line-side application. The solution integrates with the factory management system and includes ID-card access control, position indicators, tiered storage management, and height-detection light curtains to improve material control, picking speed, inventory accuracy, and plant space utilization.

5 m

Automated Storage Height

300kg

Load Capacity

Line-Side Warehouse

Process Material Management

Zero Picking Errors

Position Indicators Reduce Errors

PROJECT OVERVIEW

Project Overview

The TPU film manufacturer originally used conventional fixed shelving to manage process line-side materials. However, the shelving occupied substantial floor space and provided an open storage environment that made it difficult to track actual quantities and access status. Because many materials looked similar, manual identification increased the risk of picking the wrong item, which could result in processing errors and significant losses. After the large 5 m, 300 kg automated storage system was introduced, materials could be systematically controlled through enclosed storage, access authorization, position indicators, tiered management, and height-detection light curtains. Integration with the factory management system further improved management accuracy and operating efficiency.

Industry

TPU Film Industry

Application

Process Line-Side Warehouse

System Specification

Large 5 m

Load Capacity

300kg

1. Project Background: High Accuracy Required for Line-Side Material Management

In TPU film production, the accuracy of line-side material management directly affects downstream processing quality and production costs. When materials are visually similar and the site lacks clear identification and systematic control, operators may select the wrong material, leading to processing errors and financial losses.

The client originally used conventional fixed shelving. Although it provided basic storage, it could not effectively track actual quantities, access records, or material status. The open shelving also made control more difficult, creating inventory discrepancies, picking errors, and wasted space in the process line-side warehouse.

This project upgraded the conventional line-side shelving to a large 5 m, 300 kg automated storage system integrated with the factory management system. Material access, user permissions, storage locations, and inventory records can now be managed more effectively.

BEFORE / AFTER

Key Differences Before and After Implementation

The operation was upgraded from fixed shelving, open access, and manual material identification to synchronized system integration, access control, position indication, and height-detection light curtain management.

Before | Conventional Fixed-Shelf Line-Side Warehouse

Before implementation, the client used conventional fixed shelving to manage process line-side materials. The shelving occupied a large floor area, and the open storage environment lacked comprehensive material controls, resulting in inventory discrepancies, picking errors, and poor space utilization.

Conventional shelving occupied excessive floor space, reducing plant utilization.
Open shelving prevented effective material control.
Actual quantities could not be accurately tracked, resulting in inventory discrepancies.
Visually similar materials increased the risk of picking errors.
Incorrect material selection could cause processing errors and significant losses.
Fixed shelving wasted space and reduced overall plant utilization.

After | Large 5 m Smart Process Line-Side Warehouse

After the large 5 m, 300 kg automated storage system was implemented, it was synchronized with the factory management system. Enclosed storage, ID-card access control, tiered management, position indicators, and height-detection light curtains made material handling more accurate, faster, and fully controlled.

Automated warehouse management is synchronized with the factory management system.
Fast storage and retrieval improve line-side picking efficiency.
Vertical storage maximizes height utilization and significantly reduces floor-space requirements.
Enclosed storage with ID-card access control secures all material transactions.
Warehouse material data is updated in real time to reduce inventory discrepancies.
Tiered management eliminates manual material identification and reduces picking errors.
Position indicators accelerate material picking.
Height-detection light curtains optimize storage locations, save space, and improve material management.

2. Management Challenges Before Automated Storage

Excessive Floor-Space Usage

Conventional fixed shelving occupied a large amount of floor space, reducing plant utilization and limiting available line-side operating space.

Insufficient Control in Open Storage

The open shelving environment lacked access authorization, making it difficult to control material status and usage.

Inventory Discrepancies

Actual on-site quantities could not be tracked in real time, causing record discrepancies and affecting preparation and management accuracy.

High Risk of Picking Similar Materials

When materials looked similar, manual identification could result in picking errors, processing mistakes, and financial losses.

3. Solution: Large 5 m, 300 kg Smart Process Line-Side Warehouse

JY STE designed a large 5 m, 300 kg automated storage system based on the TPU film manufacturer’s process line-side requirements. The system synchronizes with the factory management system so material data can be updated in real time, reducing inventory discrepancies. Enclosed storage with ID-card access control strengthens material security, while tiered management and position indicators minimize manual identification, accelerate picking, and reduce errors. Height-detection light curtains optimize storage locations, save space, and improve material management efficiency.

Factory Management System Integration

The automated warehouse is synchronized with the factory management system, allowing real-time material updates and reducing inventory discrepancies.

Enclosed Access Control

Enclosed storage with ID-card login strengthens access control and reduces unauthorized access and incorrect picking.

Tiered Management and Position Indicators

Tiered management and position indicators eliminate the need for manual material identification, accelerating picking and reducing errors.

Height-Detection Storage Location Management

Height-detection light curtains assign storage locations according to material height, reducing wasted space and improving material control.

4. Improvements After Automated Storage Implementation

Significantly Reduced Floor-Space Usage

Vertical storage maximizes available height, reduces the floor area required by fixed shelving, and improves plant space utilization.

100% Controlled Material Access

Enclosed storage with ID-card authorization provides fully controlled material access and a cleaner, more professional work environment.

Reduced Inventory Discrepancies

Warehouse material information is updated in real time and synchronized with the factory management system, reducing differences between physical stock and system records.

Reduced Picking Errors

Tiered management and position indicators reduce manual judgment, making material picking faster and more accurate.

Improved Storage Location and Space Efficiency

Height-detection light curtains manage storage locations and material heights, improving the efficiency of warehouse space allocation.

TPU LINE-SIDE STORAGE VALUE

5. Upgrading Line-Side Storage from Conventional Shelving to Smart Material Control

The key requirements for a TPU film process line-side warehouse are material accuracy, real-time information, and controlled access. When materials look similar, relying only on manual judgment can lead to incorrect picking and serious losses once the wrong material enters production. With the large 5 m, 300 kg automated storage system, factory-system synchronization, enclosed access control, position indicators, tiered management, and height-detection light curtains transformed the original open-shelf process into a traceable, guided, and controlled smart storage operation.

System Synchronization

The automated warehouse connects to the factory management system for real-time material updates.

Access Control

ID-card login and enclosed storage strengthen material access security.

Position Indication

Tiered management and position indicators reduce manual judgment and picking errors.

BENEFITS

Implementation Benefits

Improved Plant Space Utilization

The large 5 m automated storage system uses vertical space and reduces the floor area required by conventional shelving.

Stronger Material Control

Enclosed storage and ID-card authorization make material access safer and fully controlled.

Reduced Inventory Variance

Real-time material updates and factory-system synchronization reduce discrepancies between physical inventory and system records.

Reduced Material Picking Errors

Tiered management and position indicators reduce manual judgment, accelerate picking, and lower the risk of selecting the wrong material.

Suitable Industries and Applications

TPU Film Industry Process Line-Side Warehouse Large 5 m Automated Storage 300 kg Material Storage Factory Management System Integration ID-Card Access Control Position Indicator Function Height-Detection Storage Location Management

JY STE SMART STORAGE SOLUTION

Need Better Material Control and Fewer Picking Errors in Your Process Line-Side Warehouse?

JY STE provides integrated automated storage, smart warehousing, and process line-side material management solutions based on material dimensions, load requirements, available plant height, access control, system integration, position indication, and height-detection light curtain requirements.

Contact JY STE | +886-4-2384-5678

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