Automating Smarter Processes for a Farming Machinery Manufacturer
Key Figures at a glance:
| Location | Ireland |
| Operational Time | 12 hours 5 days a week (inbound 12 hours per day) |
| Throughput INN | 30 pallets per hour |
| Throughput OUT | 15 pallets out per hour constant |
| Taxis | 5 |
| Building Height | 12.2 metres |
| VTUs | 2 |
| Inbound Locations | 1 |
| Outbound Locations | 1 |
| Specials | Hazardous goods warehouse and prepared to triple throughput figures |
The Moffett Taxi system was used to transform storage and operational efficiency at Irish Farming Machinery (IFM), delivering advanced picking capabilities, increased density and enhanced safety.
Project Overview
Based in Dunleer, Ireland, Irish Farming Machinery (IFM) is an industry leader in the manufacturing and supply of farming machinery. With their business growing exponentially, their existing setup restricted their ability to handle increasing inventory demands.
IFM’s warehousing operations became increasingly challenging due to insufficient storage capacity and the restrictive nature of the
manual operations they had in place. With these challenges in-mind, IFM partnered with Moffett Automation to design and
implement a fully automated storage system tailored to their needs.
Moffett Automation was presented with three key objectives:
- To overhaul IFM’S warehouse layout.
- To integrate advanced automation.
- To provide a scalable solution that would enhance their storage density, improve their picking operations and ensure the highest safety standards.
Challenges Presented
IFM faced several critical challenges in fulfilling their warehousing
operations:
- IFM’s primary challenge was its limited storage capacity. With only 1,000 pallet spaces available, they required a major
expansion to meet growing inventory demands. - IFM needed to facilitate 4 different operations in one warehouse. To address this, they needed a sophisticated picking area on a
mezzanine floor for their shop, which serves customers on a daily basis. - Ensuring the highest levels of safety throughout their warehouse was another key challenge, particularly with the introduction
of automated systems and increased personnel interaction. - Additionally, the facility needed seamless integration with their Warehouse Management System (WMS) to enable smooth
operations across all aspects of inventory management.
Storage Transformed
Moffett Automation delivered a comprehensive solution, addressing IFM’s
storage and operational challenges with a bespoke automated system:
Moffett Taxi™
5 Taxis were deployed, delivering pallets to all four operational requirements of the warehouse.
Moffett Conveyor™
This was complemented by advanced conveyor systems that integrated seamlessly with specialised fire safety doors and existing warehouse infrastructure.
Moffett VTU™
Vertical lift systems were introduced to optimise vertical space utilisation, enhancing overall storage capacity.
Moffett WCS™
We implemented a robust software suite that included pallet storage management, traffic control, and route scheduling, all fully integrated with Total Packaging’s existing WMS. This software not only managed the physical movement of pallets but also ensured that during peak times, the system could handle incoming volumes as high as 66 pallets per hour.
Safety measures
The project also included the installation of safety measures such as fencing and light curtains, ensuring that the solution was not only effective but also scalable and future-proof. This is combined with the fact that automated systems reduce workplace accidents by up to 70%.
Technical online support
Moffett Automation provided a 24/7 online support system staffed by their own experts to ensure continuous, uninterrupted operation and quick resolution of any issues.
Local mechanical support
The Moffett Automation system is supported by a leading local service partner who will provide preventive maintenance and rapid 24 hour onsite response if and when required.
Advanced Picking Stations
67 specialized picking stations were implemented to fulfill shop orders, greatly improving stock
accuracy.
Project Results
The implementation of the Moffett
Taxi™ system at Irish Farming
Machinery resulted in significant
enhancements to their warehouse
operations, delivering measurable
improvements.
One of the most impactful outcomes was the dramatic increase in storage density. IFM’s warehouse capacity expanded from 1,000 pallet spaces to 6,209. This optimization not only allowed IFM to handle its growing inventory demands but also created room for future expansion, ensuring that the system remained scalable and adaptable to their evolving needs
The streamlined picking operations brought about by the 67 specialized picking stations greatly enhanced order fulfillment processes. These stations improved the speed and accuracy of picking tasks, reducing processing times and ensuring that orders could be completed more efficiently.
By integrating seamlessly with IFM’s Warehouse Management System (WMS), the automated storage solution provided real-time inventory tracking and improved overall supply chain visibility. This integration allowed for better decision making and a more cohesive approach to warehouse management.
Safety was another major area of improvement. Moffett Automation’s robust safety measures, safety wires, and magnetic locks, minimized operational risks and ensured a secure working environment for warehouse staff. Additionally, the system’s automated energy-saving features reduced operational costs by optimizing power usage during idle periods, making the warehouse not only safer but also more cost-effective.
Feedback from IFM has been overwhelmingly positive. The system’s reliability and redundancy features ensured uninterrupted operations. By transforming its warehouse with Moffett Automation’s solutions, IFM is now better equipped to meet its operational goals and drive future growth.
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Get in touch and our team of engineers will identify how efficient your current storage system is and detail the benefits of automated storage solutions to save floor space and time, reduce costs, increase operational speed and return on investment.
