Propac

View the details behind our VLM Case Study

Propac is one of Asia Pacific’s largest and most respected manufacturers, importers, distributors and suppliers of packaging related products and services

Project Background

Propac, a leading packaging supplier, faced mounting pressure to streamline their parts management operations. With thousands of small consumables and machinery spare parts to track, their existing manual shelving system was creating significant bottlenecks. Inventory inaccuracies had become commonplace, leading to misplaced stock, unexpected shortages, and frustrated service technicians waiting on critical components. Fulfillment times lagged behind expectations, impacting customer satisfaction and field service efficiency. The team recognized the urgent need for a modernized storage solution to regain control and accelerate operations.

Project Details

Constraints

The project faced significant constraints driven by Sydney’s premium industrial real estate costs. Every square meter of floor space carried substantial value, making a massive reduction in storage footprint essential to free up room for revenue-generating production activities. However, shrinking the footprint couldn’t come at the expense of functionality. Seamless integration with existing ERP software was non-negotiable—the team required real-time stock visibility to eliminate guesswork, enable accurate demand planning, and ensure service technicians could trust inventory data without manual verification.

Implementation

The implementation delivered transformative results through the strategic deployment of two Vertical Lift Modules. This consolidated storage solution reclaimed approximately 85% of previously occupied floor space—returning valuable real estate to production operations and dramatically reducing warehouse congestion. To address the challenge of managing thousands of small parts, pick-to-light technology was integrated into the system. This visual guidance directs operators to exact item locations, virtually eliminating picking errors and achieving an impressive 99.9% accuracy rate across all fulfillment activities.