In today’s highly competitive market, efficient logistics and warehouse management are critical to corporate competitiveness. A leading European plastics manufacturer, with operations spanning Europe, Asia, Africa, the Americas, the Middle East, and New Zealand, serves millions of B2B customers while managing over 2,200 SKUs across more than 33,000 storage locations. Its warehouse system has long faced immense operational pressure.

Lead Intelligent Equipment’s subsidiary, Lead Logistics, has accumulated years of experience in the logistics sector. Leveraging deep technological expertise and hands-on practice, it designed a tailored smart warehouse upgrade solution for the company, enabling comprehensive operational transformation.

Targeted Insights：Solving Warehousing Pain Points

Traditional industrial material warehousing faces multiple bottlenecks:

• Low automation levels: Heavy reliance on manual labor leads to high labor intensity and costs.
• Delayed order response: Excessive human intervention slows order processing and prevents closed-loop traceability, directly affecting customer service quality.
• Limited scalability: Existing solutions lack flexibility and expansion potential, constraining future business growth.

To address these challenges, Lead Logistics delivered a customized intelligent warehousing solution.

Dense Storage Design：Maximizing Space Efficiency

Based on SKU variety and in/out frequency of plastic finished and semi–finished products, Lead Logistics implemented a “heat zone” management strategy within the warehouse. Twenty-seven four-way shuttle vehicles were deployed, capable of flexible lateral and vertical movement. Following system commands, they execute precise cross-aisle and cross-level material handling, fully utilizing warehouse space while significantly increasing storage capacity and operational efficiency.

Goods-to-Person Picking：Streamlining Workflow for Greater Efficiency

In addition to dense storage, multiple goods-to-person picking stations have been deployed, coordinated through the Warehouse Management System (WMS) for centralized task management.

Wave planning function improves order fulfillment accuracy, reduces the frequency of inbound and outbound operations, and lowers equipment workload. Simultaneously, travel time for warehouse personnel is minimized, significantly enhancing picking efficiency and accuracy.

Cross-Industry Adaptability：Expanding Application Scenarios

This intelligent warehousing solution is not limited to the plastics industry; it offers broad applicability across finished and semi-finished goods warehouses in multiple sectors:

• Food Industry: Ensures safe storage, accelerates logistics, and meets stringent requirements for food safety and turnover efficiency.
• Materials Industry: Enables precise inventory management and rapid order fulfillment, strengthening competitiveness in the materials market.
• Chemical Industry: Supports safe storage and efficient logistics operations, complying with strict handling and storage standards for chemical products.

The smart warehouse solution customized by Lead Logistics effectively addresses traditional warehousing challenges, delivering substantial economic and operational benefits. From consulting and design to tailored solutions and system upgrades, it acts as the “intelligent brain” of modern factories. With operations across more than 18 countries and regions, and robust global delivery capabilities, LEAD provides comprehensive intelligent logistics solutions for industries including new energy, automotive, manufacturing, chemicals, materials, consumer goods, and food.