Optimization of FOP's Systems in Automated Warehouse Management
A client operating in the internal logistics sector was experiencing persistent inefficiencies across its automated warehouse systems. Frequent equipment breakdowns and machine stoppages led to high maintenance costs and prolonged downtime, compromising overall productivity and increasing operational expenses. The client required a comprehensive solution, not only to address immediate technical failures but also to eliminate root causes tied to structural and system-level inefficiencies. We assumed full responsibility for the system’s performance, starting with the organization and scheduling of preventive maintenance. Working closely with mechanical and electrical engineers, we co-designed structural improvements to stabilize operations and eliminate recurring issues. Our intervention included a full electrical system upgrade, enhancements to the warehouse management software, and the integration of energy recovery modules that significantly reduced energy loss and lowered power consumption. In parallel, we supported the client in accessing public funding and tax incentives, optimizing the project from a financial perspective as well. As a result, the warehouse achieved a new level of operational efficiency: • Downtime was drastically reduced • Systems now operate autonomously during nights and weekends • Maintenance costs dropped significantly • Overall energy consumption decreased by approximately 30% The project transformed the warehouse from a high-cost, high-maintenance liability into a stable, scalable, and energy-efficient operation.