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CloseSolutions that move business forward: BusMarket Group’s experience
BusMarket Group, a leader in the distribution of auto parts in the western region of Ukraine and a strategic partner in the auto repair industry, turned to KAPELOU with an urgent need for comprehensive warehouse automation. The distributor offers an assortment of more than 150,000 SKUs to meet the needs of passenger cars and light commercial vehicles.
We have already worked with the customer on a number of projects. More than 7 years of fruitful cooperation have resulted in the implementation of a number of projects in different cities of Ukraine. Each of them involved the implementation of solutions to automate internal warehouse processes, increase productivity, and speed up the processing of goods.
This time the main task was to ensure the scalability of existing warehouse processes, which was successfully achieved by means of a comprehensive concept developed in close cooperation with the customer. The solution is based mainly on the use of KAPELOU conveyor systems, which helped to modernize warehouse operations, increase warehouse throughput, and speed up order processing.
After a detailed technical audit and assessment of the premises, the KAPELOU team, together with the customer, identified critical areas for equipping them with conveyor systems. We selected the equipment that fully meets the needs of the warehouse and helps to increase the speed of order processing, taking into account the growing assortment. After the concept was approved, we:
- manufactured and assembled the conveyor modules
- ordered equipment not from our production range, and fully integrated the designs into existing processes
Successful commissioning confirmed the system’s readiness for stable and efficient operation in the real conditions of the logistics hub.
Conveyor equipment for the warehouse and technologies used in the project:
– roller driven conveyor
– inclined belt conveyor
– spiral conveyor
– gravity racks
– Pick-by-Light technology
The feedback from Vitaliy Topolyuk, Director of Logistics at BusMarket Group, brings a deep understanding of how modernizing conveyor equipment can significantly improve warehouse efficiency.
The main results of the KAPELOU automated system implementation:
- 3x increase in the productivity of the receiving and picking areas.
- 2x faster replenishment of the storage area.
- 2x increase the area of sorting goods by orders.
Due to the complex automation, the supply of trays to all levels of the mezzanine is much faster, and the flow of goods is separated; additional buffers for accumulating trays after picking and cells for sorting goods by orders have been installed. - Optimization of the order picking process, especially for urgent orders.
- Significant reduction in staff routes and improvement of working conditions.
Vitaliy Topoliuk emphasizes that this upgrade is a natural stage in the evolution of the business, due to the company’s growth and expansion of warehouse operations.
- The spiral conveyor, mounted inside the mezzanine for optimal space utilization, transports trays to the storage area. The equipment also acts as a buffer, allowing trays to accumulate along the entire length and gradually replenish the mezzanine at all levels. Thanks to the new equipment, the speed of replenishment of the mezzanine has increased significantly: the spiral conveyor processes up to 1600 trays per hour.
- An additional roller conveyor in the receiving area allowed the flow of goods in the warehouse to be separated. Operators take the goods from the pallets and place them in trays, which are then placed on gravity racks. An inclined belt conveyor installed over the aisle to optimize space and safety for personnel and special equipment. A diverter at the end of the line directs the trays to the elevator, which takes them to the desired mezzanine level.
Automated return of empty containers
At the mezzanine level, trays with goods and empty trays are transferred to the upper level of the roller conveyor, while cases with picked orders are transferred to the shipping area via the lower level.
Pick-by-Light technology in the sorting area
Thanks to the modularity of the equipment, the number of gravity racks installed during the previous project was increased and the Pick-by-Light system has simplified, accelerated, and made sorting more accurate, minimizing operator routes. The LED lighting immediately indicates where to place the tray.
Roller conveyors for processing urgent orders
We installed a roller conveyor in the warehouse to automate the movement of urgent orders that do not require sorting. After being transported by the conveyor from the receiving area, they are placed on pallets and prepared for shipment.
In combination with the “Goods to Person” technology, the conveyor equipment allowed the customer to quickly and efficiently scale warehouse processes, increase warehouse throughput, and optimize employee routes.
The project, implemented in close cooperation with the customer, showed how automation can be used to improve warehouse processes in a few months:
- increase the productivity of warehouse areas
- improve the efficiency of the logistics hub
- make the working environment more comfortable
We would like to thank BusMarket Group for their trust and long-term cooperation, which was the key to the successful implementation of this solution!
