Space, speed, and accuracy are critical factors in manufacturing and warehouse operations. As inventory grows and production lines become more complex, traditional shelving systems often fall short. Vertical lift modules (VLMs) offer a solution by transforming how companies store, access, and manage materials-using automation and vertical space to drive efficiency.

Summary:

• VLMs automate storage and retrieval, improving picking speed, accuracy, and safety for manufacturing and warehouse operations.
• Flexible tray configurations and intelligent software support a wide range of applications, from line-side storage to tool cribs and batch picking.
• Shoplogix integrates with VLMs to provide real-time data, performance analytics, and continuous improvement for inventory management.
  

How Vertical Lift Modules Work and Why They Matter

A vertical lift module is an enclosed, automated storage system made up of two columns of trays with a central elevator mechanism. Items are stored on trays stacked vertically, and when an operator requests a part-using a touchscreen, barcode scan, or software command-the VLM retrieves the correct tray and delivers it to an ergonomic access window. This “goods-to-person” approach eliminates time-consuming searching and reduces physical strain on workers.

The system’s intelligent software detects tray heights and dynamically assigns storage locations, maximizing capacity and minimizing wasted space. VLMs can be installed in heights ranging from about 11 to over 50 feet, making full use of available ceiling height.

5 Key Benefits of VLMs in Manufacturing and Warehousing

1. Maximizing Floor Space and Storage Density

By stacking trays vertically, VLMs reclaim up to 85% of floor space previously occupied by conventional shelving. This dense storage is especially valuable for slow- or medium-moving SKUs, spare parts, tools, and components that don’t require constant access.

2. Improving Picking Speed and Accuracy

VLMs automate the retrieval process, presenting the right item at the right height. This reduces picking errors, increases throughput (with some systems achieving up to 140 trays per hour), and supports batch picking for small items. The result is faster order fulfillment and lower labor costs.

3. Enhancing Safety and Ergonomics

Features like light curtains, shutter doors, and ergonomic access windows protect operators from injury and minimize repetitive reaching or bending. The enclosed design also secures inventory, reducing the risk of loss or damage.

4. Supporting Flexible and Dynamic Storage Needs

VLMs accommodate a wide range of part sizes and weights, with tray payloads often exceeding 2,000 lbs. Tray heights are adjustable, and systems can be configured for single or dual delivery bays, internal or external picking, and integration with existing workflows.

Common Applications for Vertical Lift Modules

VLMs are used in diverse manufacturing and logistics settings, including:

• Line-side storage: Quick access to essential materials and components reduces downtime and keeps production moving.
• Tool cribs: Secure, organized storage for tools and equipment, with access tracking for accountability.
• Batch picking: Efficient handling of small parts for order fulfillment or kitting processes.
• Spare parts and maintenance: Organized, accessible storage for maintenance, repair, and operations (MRO) inventory.
• E-commerce and retail: Fast, accurate picking for a wide range of SKUs in fulfillment centers.
• Point-of-use storage: Placing VLMs near work cells or assembly lines to minimize travel time and improve efficiency.

Integrating VLMs with Digital Platforms for Greater Value

The true potential of VLMs is realized when they are connected to inventory management, ERP, and MES systems. Integration allows for real-time inventory tracking, automated order processing, and data-driven decision-making. Operators can manage pick lists, monitor inventory levels, and generate reports directly from the VLM’s intuitive interface or through connected software.

Shoplogix offers solutions that integrate with VLMs, providing real-time analytics, performance dashboards, and automated alerts. This enables manufacturers to monitor picking rates, identify bottlenecks, and drive continuous improvement in storage and retrieval processes.

Considerations for Implementing Vertical Lift Modules

When planning a VLM installation, manufacturers should assess:

• Inventory profile: Analyze SKU sizes, weights, and movement frequency to determine optimal tray configuration and system height.
• Workflow integration: Position VLMs near production lines, shipping areas, or maintenance departments to maximize efficiency.
• Software compatibility: Ensure the VLM can connect to existing ERP, MES, or WMS platforms for seamless data exchange.
• Operator training: Provide thorough training on system use, safety features, and troubleshooting to maximize ROI and minimize downtime.

Final Thoughts on Vertical Lift Modules

As manufacturing and warehousing become more complex, the need for flexible, automated storage grows. VLMs offer a scalable solution that adapts to changing inventory profiles and production demands. With advances in intelligent software, mobile VLMs, and deeper integration with digital platforms, these systems will continue to play a central role in efficient, data-driven operations.

What You Should Do Next 

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