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Rubber & Plastic Products Manufacturing

Third Project for a Leading TPU Film Manufacturer

Process Line-Side Warehouse

Features: Large 5-Meter Automated Storage System for Centralized Management of Semi-Finished Shoe Materials; Shoe Material Classification Management to Improve the Handling of Diverse Item Types; Position Indication Function to Reduce Manual Judgment Errors; Access Control Mechanism to Strengthen Valuable Material Control; Vertical Storage Design to Reduce Floor Space Occupancy; Real-Time Material Information Updates to Reduce Inventory Discrepancies; Fast Material Search and Inbound/Outbound Operations to Improve Line-Side Work Efficiency

Description

This project is the third 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 the centralized storage, classified management, and inbound/outbound operations of semi-finished shoe material products.

Before the upgrade, the customer stored semi-finished shoe materials on conventional steel racks. Since the materials involved a wide variety of types and shoe size specifications, the existing storage method often led to difficulties in manual identification, time-consuming material searches, limited control over valuable materials, excessive floor space usage, and inventory discrepancies.

Based on the customer’s on-site requirements, JY STE Technology introduced a large vertical smart storage system equipped with position indication, access control, real-time inventory updates, and a vertical storage design. The solution helps overcome the limitations of traditional warehouse management.

After implementation, semi-finished shoe materials can be managed through a centralized, compartmentalized, and access-controlled system. This improves material search efficiency and inventory accuracy while strengthening the security of valuable material storage and retrieval. As a result, the semi-finished shoe material warehouse becomes more accurate, secure, and efficient.

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TPU FILM LINE-SIDE STORAGE CASE STUDY

TPU Film Manufacturer – Third Project | Production Line-Side Warehouse
Large 5 m, 300 kg Automated Storage System Case Study

This project is the third automated storage implementation for a major TPU film manufacturer, designed for a production line-side warehouse. The client previously stored semi-finished shoe materials on conventional iron racks. Because the materials varied widely in type and shoe size, workers found them difficult and time-consuming to identify. Valuable materials were also stored in open areas, making access control and management difficult. Apex evaluated and implemented a large 5 m, 300 kg automated storage system featuring centralized storage, location indicators, compartmentalized management, access authorization, and real-time inventory updates. The solution reduced floor-space usage, improved inventory accuracy, and shortened material retrieval time.

5 m

System Height

300kg

Load Capacity

Semi-Finished Shoe Materials

Centralized Storage Management

Access Control

Valuable Material Access Control

PROJECT OVERVIEW

Project Overview

The third project for this TPU film manufacturer focuses on managing semi-finished shoe materials in a production line-side warehouse. Before implementation, the materials were stored on conventional iron racks. The wide variety of material types and shoe sizes made identification and retrieval time-consuming, while valuable materials kept in open areas were difficult to control. After introducing the large 5 m, 300 kg automated storage system, the materials could be centrally managed with location indicators, compartmentalized storage, access authorization, and real-time inventory updates, improving retrieval efficiency, inventory accuracy, and plant-space utilization.

Industry

TPU Film Industry

Application

Production Line-Side Warehouse

System Specification

Large 5 m System

Load Capacity

300kg

1. Project Background: More Accurate Line-Side Management for Semi-Finished Shoe Materials

The production line-side warehouse manages a wide range of semi-finished shoe materials. Because material types, shoe sizes, and processing conditions vary considerably, conventional iron-rack storage required workers to spend excessive time identifying, locating, and retrieving items, increasing the risk of picking errors and inaccurate management.

In addition, some semi-finished shoe materials are high-value items. When stored in open areas, access permissions are difficult to control, and actual quantities and material movements cannot be tracked in real time. Delayed inventory updates can therefore cause discrepancies between physical stock and system records, affecting production preparation efficiency.

The large 5 m, 300 kg automated storage system centralizes semi-finished shoe materials and integrates classification, access control, location indication, and real-time inventory updates within one intelligent storage platform.

BEFORE / AFTER

Key Differences Before and After Implementation

The operation was upgraded from conventional racks, manual identification, and open-area storage to centralized management, location indication, access control, and real-time inventory updates.

Before | Conventional Iron-Rack Storage

Before implementation, semi-finished shoe materials were stored on conventional iron racks. The wide variety of material types and shoe sizes required workers to identify items manually. Valuable materials were also kept in open areas, making management and inventory control difficult.

Semi-finished shoe materials were stored on iron racks
Material types and shoe sizes varied widely, making identification difficult
Valuable materials were difficult to manage in open areas
Conventional racks occupied substantial floor space, resulting in low plant utilization
Actual quantities could not be tracked accurately, causing inventory discrepancies

After | Large 5 m Intelligent Line-Side Warehouse

After implementing the large 5 m, 300 kg automated storage system, semi-finished shoe materials could be managed centrally and separated by designated storage locations. Access to valuable materials could be restricted through authorization controls, while real-time inventory updates reduced discrepancies between physical stock and system records.

The large 5 m automated storage system centralizes semi-finished shoe materials
Location indicators support separated storage without manual identification
Workers can quickly locate the required materials
Authorization control restricts valuable materials to approved personnel
Vertical storage makes full use of the plant height
Floor-space requirements are greatly reduced, improving plant utilization
Inventory information is updated in real time, reducing record discrepancies

2. Management Challenges Before Implementation

Limitations of Conventional Iron Racks

Semi-finished shoe materials were stored on conventional iron racks without a detailed, systematic classification and management method.

Difficult Manual Identification

The wide variety of material types and shoe sizes required workers to identify items manually, increasing retrieval time and the risk of picking errors.

Insufficient Control of Valuable Materials

Valuable materials were stored in open areas, making access permissions and usage tracking difficult to manage.

Excessive Floor Space and Inventory Discrepancies

Conventional racks occupied substantial floor space and did not provide real-time quantity tracking, resulting in low plant utilization and frequent inventory discrepancies.

3. Solution: Large 5 m, 300 kg Intelligent Line-Side Storage System

Based on the production line-side warehouse requirements, Apex implemented a large 5 m, 300 kg automated storage system. The system centralizes semi-finished shoe materials and uses location indicators for separated storage, enabling workers to find materials quickly without relying on manual identification. Valuable materials are protected through access authorization, while vertical storage makes full use of the plant height and significantly reduces floor-space requirements. Real-time inventory updates also help minimize discrepancies between physical stock and system records.

Centralized Management of Semi-Finished Shoe Materials

The large 5 m automated storage system centralizes semi-finished shoe materials, replacing dispersed rack storage and improving retrieval efficiency.

Location Indication and Separated Storage

Location indicators support separated storage and allow workers to find materials quickly without manual identification.

Access Control for Valuable Materials

Authorization controls ensure that valuable materials can only be accessed by approved personnel, improving security.

Vertical Use of Plant Height

Vertical storage fully utilizes the available plant height and significantly reduces the floor space required by conventional racks.

4. Improvements After Implementation

Improved Material Management

Semi-finished shoe materials were upgraded from conventional rack storage to centralized management in a large 5 m intelligent storage system.

Faster Material Retrieval

Location indication and separated storage reduce manual identification and enable faster retrieval.

Stronger Control of Valuable Materials

Access authorization restricts valuable materials to approved personnel, improving security and management reliability.

Improved Plant-Space Utilization

Vertical storage makes full use of the plant height and significantly reduces floor-space usage.

Reduced Inventory Discrepancies

Real-time inventory updates make actual quantities easier to track and reduce discrepancies between physical stock and system records.

TPU THIRD CASE STORAGE VALUE

5. From Conventional Racks to Intelligent Line-Side Material Management

The key challenge in this third TPU film project was managing a wide variety of semi-finished shoe materials across different sizes, including high-value items. Conventional iron racks and open-area storage led to slow retrieval, difficult identification, insufficient access control, and inventory discrepancies. The large 5 m, 300 kg automated storage system introduced centralized management, location indication, separated storage, access authorization, and real-time inventory updates, making line-side material management faster, clearer, and more secure.

Centralized Management

Semi-finished shoe materials are stored centrally instead of being dispersed across conventional racks.

Access Control

Valuable materials can only be accessed by authorized personnel.

Location Indication

Separated storage with location indicators reduces manual identification and speeds up retrieval.

BENEFITS

Benefits Summary

Improved Retrieval Efficiency

Location indicators and separated storage enable workers to quickly find the required semi-finished shoe materials.

Enhanced Material Security

Access authorization controls valuable materials and reduces the risks associated with open-area storage.

Improved Plant-Space Utilization

Vertical storage fully utilizes the plant height and significantly reduces floor-space requirements.

Reduced Inventory Variance

Real-time inventory updates improve quantity tracking and reduce discrepancies between physical stock and system records.

Applicable Industries and Applications

TPU Film Industry Production Line-Side Warehouse Semi-Finished Shoe Material Management Large 5 m Automated Storage System 300 kg Material Storage Location Indicator Access Control Real-Time Inventory Updates

APEX SMART STORAGE SOLUTION

Need to Improve Material Retrieval, Access Control, and Inventory Accuracy?

Apex provides integrated automated storage and intelligent line-side material management solutions based on material categories, dimensions, load requirements, plant height, access-control needs, location indication, and real-time inventory update requirements.

Contact Apex Equipment | +886-4-2384-5678

Relevant actual results