Italian mega distributor VIPA is currently constructing its third high-bay automated warehouse, increasing its storage capacity by an additional 30,000 pallet spaces to 150,000 spaces in total – enabling it to further expand its product range and stock capability.
VIPA SpA can supply over 65,000 different products including different sizes, coatings and materials. It moved to its current head office in Rolo, Emilia-Romagna, in 2001 and began with one high-bay warehouse, which was 135m long and 35m high and included 5 automated aisles. By 2007 the company had reached its warehouse capacity and needed to expand. It then added a second high-bay warehouse that was the same dimensions, but this time included 7 automated aisles – with all 12 aisles across both warehouses working in synchronisation to deliver the products to the pickers who then created the final order.
Now VIPA is adding a third warehouse – again with the same dimensions – which will see the company increase its storage capacity by 25%. The new warehouse will also synchronise with the other two warehouses, but it will differ in the fact it will be fully automated. “There will be no manual movement of boxes in the new warehouse, with the system weighing incoming and outgoing pallets to make sure orders are correct and complete,” explains Gianluca Collepardo, export manager at VIPA. “Not having a human component regarding preparation is something completely new for us, but it is necessary to help improve the efficiency of the picking process.”
The introduction of the new warehouse will mean VIPA has a totally automated 24hr system – the machines will be operational round the clock. At night the machines will work on optimising the goods spots; not only on the basis of actual orders, but also on probability of potential ones.
Construction on the new high-bay automated warehouse is due to be completed by September 2018. “Originally the warehouse was scheduled to be completed by the end of summer,” points out Gianluca. “However, in recent months we have experienced terrible weather in this part of Italy, with a lot of storms and rain, which meant construction kept having to be put on hold. Hopefully, with the Italian summer now here, we will stay on track.”
Gianluca is very much aware that having the construction complete and having the warehouse fully operational are two completely different things. “It is like a computer, at the moment we are just fitting the hardware, the next step is the software,” states Gianluca. “Everything will need to be tested and tested again. It is vital to make sure everything is working together perfectly.”
Once construction is complete and tests have been carried out, the next step will be loading the goods into the correct locations, which VIPA hopes will be done before the end of the year. “We are planning to have filled the new warehouse, and have it fully operational, by Christmas 2018. It is important to have continuity with the customer and you need to be a stable supplier, so we do not want to rush introducing the warehouse until it is 100% effective. Our aim is to supply a wide range of products with a quick service and by increasing our warehouse capacity we can have a bigger stock, so whatever the customer needs, we have it.”
Alongside the extra warehouse there will also be an additional area where shipping and preparation for Kanban will be based. VIPA will also move the entrance to the site to the opposite side of the building, so it connects directly with the main road – making it easier for trucks to gain access.
Close to customers
VIPA supplies both trade and industry, with end users accounting for 30% of the business and trade representing the remaining 70%. “We only work with the big end user companies, there needs to be a certain volume before we will work with an end user,” points out Gianluca. “The cost of supplying €10 of products is the same for us as supplying a pallet, which is why we have minimum order values and minimum item numbers.”
In addition to its head office in Italy, VIPA has three divisions in Spain, France and Germany that act as fully operational companies with a reception, offices and stock. “We service these divisions from the main head office here in Rolo,” explains Gianluca. “That way the branch office can supply their own products to the customers and if they don’t have the products we supply it directly.”
VIPA also has a Chinese division that imports goods directly from the Far East to customers, as well as a task office in the Czech Republic to serve the eastern European market. “There is no stock in the task office,” mentions Gianluca. “They are just working with the customers and then provide stock through the main office.”
Quality assurance
VIPA also has a fully equipped laboratory that can conduct a wide variety of tests including tensile testing, zinc plate testing, micro inspection and salt spray testing. The company points out it can carry out all necessary tests to guarantee the quality of the products, according to certified and known norms.
VIPA is also certified as a producer of structural bolts, according to EN 15048:2007 standards, with the SB screw. The SB screw is supplied with CE Marked nuts in accordance with the construction standards 89-106 and 109 EN-1 and 2 – part of the category of high strength bolts. From its expanding range and availability, VIPA offers prompt delivery in zinc plated and HDG. Another, recently released, range is construction bolting in HV kits according to EN 14399. The catalogue includes all the sizes of hex head bolts, in plain and galvanised, from M12 to M36. The core business of VIPA is the 8.8 standard metric bolt classes, but the company also has a very interesting range from M2.5 up to M56 in various lengths. Larger sizes can also be manufactured upon demand.
2018 positive so far
VIPA has reported a positive start to 2018 and with the investment in the new warehouse, it is hoping to create more opportunities in the market. “At the moment everybody is doing fine and there is enough business to go around. However, it is during the hard times when business is not so easy that the truly good companies stand out,” states Gianluca. “As a big stock holder we already have an in-depth stock, so we can act as a pillow for the customer – gradually harmonising the price if there are fluctuations in the market, such as raw materials prices or the currency market.”
Gianluca concludes: “As a company we are always looking to expand and adding the new warehouse will give us another weapon to compete in the market. The policy of the ownership is to reinvest into the company because the higher the service quality and product range, the more you are able to achieve that other competitors cannot.”
Will joined Fastener + Fixing Magazine in 2007 and over the last 15 years has experienced every facet of the fastener sector - interviewing key figures within the industry and visiting leading companies and exhibitions around the globe.
Will manages the content strategy across all platforms and is the guardian for the high editorial standards that the Magazine is renowned.
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