As a top-tier manufacturer of industrial-grade building materials, the client specializes in products packaged in jumbo sacks and bulk bags. The legacy warehouse relied on manual stacking and forklift operation, which led to several persistent challenges:

• Disorganized material placement and wasted floor space

• Packaging wear and product degradation due to improper stacking and environmental exposure

• High error rates in order picking and difficulties with stocktaking

• Limited scalability to support future production expansion

To overcome these limitations and align with its smart manufacturing roadmap, the company sought a comprehensive, standardized, and intelligent warehousing solution capable of supporting business growth and lean operations.

• Traditional floor stacking unable to meet high-throughput, high-mix material handling needs

• Manual operations prone to inefficiencies and errors

• Lack of digital infrastructure for SKU management, inbound inspection, and route optimization

• Tight delivery timeline and complex pallet specifications (bulk bags of varying shapes and sizes)

1. Four-Way Shuttle High-Density Storage System
The solution includes three four-way shuttles and two high-speed vertical lifts operating across six-tier racking with over 3,000 storage positions, including 174 custom pallet slots tailored to irregular packaging. Integrated with ZIKOO’s proprietary WMS and WCS platforms, the system delivers intelligent zone management and dynamic slot allocation—enabling high-density, high-efficiency, and high-precision operation.

2. Automated Inbound Quality Check
The system incorporates automated shape and weight verification modules to ensure every pallet meets storage criteria before entering the system.

• Compliant items → Auto storage

• Non-compliant items → Rejected with system alert and exception workflow
  This ensures accurate inbound records and prepares the system for reliable inventory tracking and dispatch scheduling.

3. Real-Time Warehouse Visualization with Digital Twin
ZIKOO deployed a real-time digital twin engine that mirrors the full 3D warehouse layout and synchronizes with live WMS/WCS data. Capabilities include:

• Real-time monitoring of equipment status, alerts, and failure points

• Full traceability of material movement and historical activity logs

• Predictive maintenance alerts to reduce unplanned downtime

• Visual dashboards to support data-driven decision-making

4. Rapid Implementation, Scalable Architecture
Built with a modular design, the system was delivered and commissioned in under 80 days. Its scalable architecture allows easy future expansion—whether upgrading shuttle capacity or adding vertical lift modules to support growing SKU complexity or production needs.