Carozzi: safe and sustainable integration to ensure excellent service for the end customer

Factory sustainability and end-customer service

In this context, Optimus was launched in 2017, not as simple project but as an integral part of the digital transformation process initiated by Carozzi using cutting-edge technology. Indeed, Optimus is the result of Carozzi's need to increase operations of its distribution center in Nos, in the province of Santiago, Chile, to flexibly adapt to its production growth, while offering an excellent and personalized service to the market at the same time.

To achieve their goals for efficiency, sustainability and safety, Carozzi chose our company, which is recognized as a leader in the field of tailor-made intralogistics solutions, able to integrate and automate all intralogistics work flows thanks to the implementation of SDM software and our systems: automated laser-guided vehicles, picking system, and an AS/RS Stacker Crane high-density automated warehouse that is 30 meters high.

Carozzi Interview from E80 Group on YouTube.

The solution was a challenge that we successfully rose to, thanks to our significant teamwork and state-of-the-art technology. In fact, the Nos distribution center ships 80% of Carozzi's total production volume and the entire process was optimized without interrupting operations.

Optimus project: an automated and integrated distribution center

The project was carried out in two phases.

In the first phase, in close collaboration with Carozzi's team, we analyzed, designed and automated all handling of pallets within the distribution center, from the reception of goods to shipping, and even the preparation of orders through innovative layer picking and case picking systems.

To date, it has enabled Carozzi to increase its shipping capacity by 35% compared to the previous system.

Another decisive element has been the option of certified loading developed by a local partner: this system allows the truck driver to view all the information relating to the order directly on his smartphone, which is then visible to the end customer as soon as the cargo leaves the factory.

The design of this integrated system ensures maximum traceability of the product handled, shortens time to market, reduces errors and waste as well the carbon footprint, and ensures the end consumer a reliable service.

The second phase of the project involved the construction of a high-density warehouse, AS/RS Stacker Crane; fully automated and integrated thanks to LGVs performing the goods handling, it allows pallets to be stacked in a manner to optimize the existing space. At 5.500 m² with 30,000 pallets, the structure has a storage capacity five times greater than the previous one and a saturation of 98%, allowing Carozzi to achieve a total capacity of more than 100.000 pallet on a 72.000 m²  area.

Thanks to the remote 24/7 customer service and continuous training, we always stand by Carozzi's side, valuing its team culture and protecting the investment over time.

Finally, thanks to the partnership with our company, Carozzi has achieved a more efficient, sustainable and safe state-of-the-art plant, which improves service to the end customer.

Highlights

• High increase in productivity and safety.
• Formation of picking pallets of mixed products ready for shipment by optimizing pallet coverage through E80 Group bin packing software.
• Reduction of time to market.
• Elimination of errors in the arrangement of the shipping order.
• Energy saving of 40% compared to manual system.
• Reduction of checks on the boxes shipped both to the distribution centre and to the end customer thanks to digital certification of truck loading.
• 3D mapping of existing warehouse that allowed:
  • Implementation with manually stored pallets to guarantee 100% operational continuity.
  • 30% reduction in project implementation time.

Watch the videos

Carozzi Video from E80 Group on YouTube.