Project Background: Challenges Faced by the Client
A leading sewing thread manufacturer was facing rapid business growth, expanding SKUs, and increasing order volumes. However, its traditional warehouse operations could no longer support efficient logistics.
Key challenges included:
Low storage density due to floor stacking
Inefficient manual picking process
High labor dependency and management complexity
Inaccurate inventory data
Inability to achieve FIFO management
To solve these issues, the client partnered with China JSSL Company to design and implement a smart warehouse solution.
(Smart warehouse solution)
Solution by China JSSL Company
Based on the client's production flow and order characteristics, China JSSL Company delivered a customized intelligent intralogistics system, including:
Multi-layer shuttle system
Pallet AS/RS system
Goods-to-person picking stations
Automated labeling and strapping system
Integrated conveyor system
The system seamlessly connects production lines with warehouse operations, forming a fully automated logistics loop.
System Design Highlights
1. High-Density Storage Design
By adopting a multi-deep shuttle storage structure, the solution maximizes vertical space utilization and significantly increases storage capacity without expanding floor area.
2. Flexible Carton Handling
The system supports multiple carton sizes and enables direct source carton storage, eliminating repacking processes and reducing labor costs.
3. Goods-to-Person Picking
With GTP stations:
Operators remain stationary
Goods are automatically delivered
Picking efficiency and accuracy are greatly improved
4. Intelligent Software Integration
The WMS and WCS systems developed and integrated by China JSSL Company ensure:
Real-time inventory visibility
Smart order batching and sequencing
Equipment coordination and scheduling
(Automated warehouse system)
(Multi-level shuttle parking garage)
(Goods to person picking)
(Automatic labeling)
(Automatic tape application)
Operational Workflow
The warehouse operates through a fully automated process:
1.Inbound
Finished products are automatically transferred from production to the warehouse system.
2.Storage
Goods are intelligently allocated based on size, turnover rate, and order demand.
3.Order Picking
Products are delivered to picking stations via shuttle system.
4.Outbound
Orders are sorted, labeled, and dispatched automatically.
(Conveyor system integration)
Project Results
After implementation, the client achieved significant improvements:
Storage capacity increased dramatically
Warehouse space reduced by over 2,000 m²
Throughput reached 2,500 cartons/hour
Picking accuracy improved to 99.999%
Labor costs significantly reduced
Additionally, the system reduced product handling damage and improved delivery speed, enhancing overall customer satisfaction.
(Factory automation)
Future Outlook: Toward Fully Integrated Smart Logistics
China JSSL Company plans to further enhance its logistics capabilities by:
Introducing TMS (Transportation Management System)
Expanding Goods-to-Person stations
Enhancing data-driven optimization
Building a fully integrated Industry 4.0 smart factory
Through continuous innovation, the company is strengthening its position as a leader in intelligent manufacturing and smart logistics within the sewing thread industry.
(Industrial automation solution)
(Intelligent logistics solution)
Conclusion
China JSSL Company continues to provide end-to-end smart warehouse solutions for manufacturing industries.
This project demonstrates how intelligent logistics technologies can transform traditional industries, delivering measurable improvements in efficiency, accuracy, and cost control.