Case History

Strada Provinciale Francesca, 7
24040 - Pontirolo Nuovo - BG

Tel: +39 0363 880024

faifiltri@faifiltri.it
www.faifiltri.it

Fai Filtri Srl

Mechanical industry

Fai Filtri has been operating since 1976 in the field of industrial filtration, boasting steady growth both in terms of turnover and number of employees. A valuable achievement has been the development, since the early 1980s, of Asian, American and, of course, European markets. An effort crowned, last year, by the opening of the new Canadian and Chinese branches with further growth in market share. In the Italian market, the major compressor manufacturers in the country have been acquired as customers and a widespread sales network has been developed that can count on numerous qualified dealers.

Products:

WMS

StockSystem

WAREHOUSE LOGISTICS MANAGEMENT

Software for the management of logistics processes.

With Replica Sistemi and technology partner Citiemme Informatica, we have found solutions that have enabled us to optimize work time and reduce errors. Widely accepted by all for its flexibility and ease of use, StockSystem has brought many benefits.

Carlo Arcari

Logistics Manager Fai Filtri Srl

Company

FAI FILTRI S.r.l. has been operating since 1976 in the field of industrial filtration, boasting steady growth both in terms of turnover and number of employees.

A valuable achievement has been the development, starting in the early 1980s, of Asian, American and, of course, European markets.

An effort crowned by the opening of the new Canadian and Chinese branches with further growth in market share.

On the Italian market it boasts among its customers the major compressor manufacturers in the country with a widespread sales network composed of numerous qualified dealers.

NEEDS

In anticipation of the plant expansion, computerized management of storage and material handling processes became necessary.

From the previous 5,200 sq. m. comprising production, material storage, logistics and office areas, this increased to the current 12,200 sq. m. divided into 4,000 sq. m. of logistics and storage and 7,000 sq. m. of production areas.

The main requirement was the implementation of software to manage the logistics and handling of items so as to reduce picking and sorting times to production lines and finished product shipping areas.

The objectives of the restructuring project were:

greater flexibility in management and interface with software already in the company (ACG)
traceability and material handling with possible picking priorities
knowledge of free cells for optimized material storage
reduction of picking errors on item and quantity
possibility of feeding the various departments while respecting the production sequence
optimization of warehouse picks to save time and means

SOLUTIONS

In relation to the set goals, various solutions were analyzed by checking mainly:

manufacturers of warehouse equipment (forklifts/shelves) who through partners could provide a complete solution including hardware and software
'Local' software houses that would implement applications tailored to our needs
specific manufacturers of warehouse software

After careful evaluation Fai Filtri, in collaboration with technology partner Citiemme Informatica, decided to implement Replica Sistemi's StockSystem solution, integrated with handheld and vehicular RF terminals to optimize and control all logistics steps.

The main factors that led to the choice were mainly two:

CITIEMME IT guaranteed certain timeframes and defined costs
REPLICA SISTEMI presented a 'road map' of developments on StockSystem that Fai Filtri deemed essential in terms of continuity and upgrades.

In December 2007, analysis of the StockSystem project began.
In March 2008 there was a Go-Live of the project.
In January 2009, RF management in the Departments was extended.

The analysis was aimed at:

the drafting of warehouse mapping by defining shelves, locations and floors.
the implementation of hardware (antennas for RF transmission, thermal printers and terminals in RF).
the analysis and activation of functions for the correct use of RF (in continuous implementation).
the application to each cell of the barcode label with location coordinates to make the warehouse compliant with the use of the system.

After the analysis, the project was started with the following operational steps:

identification of all product bins and containers by barcode.
customization of print layouts, pick lists and labels
training of personnel in the use of the RF with the supervision of a Replica Sistemi systems engineer for any doubts or questions
loading of materials in their locations

Eventually leading to the use of the computer system for all planned procedures.

Processes activated with StockSystem:

customization of print layouts, pick lists and labels.
instruction of personnel in the use of the RF with the supervision of a Replica Sistemi systems engineer for any doubts or questions.
loading of material into their locations.
acceptance and receipt of incoming material
material storage
internal movements to and from production lines
preparation of picking lists for production and/or shipments based on picking priorities (fifo or department)
calculated rotation indexes to optimize times
calculated rotation indexes to optimize times
data exchange interfaces with management systems already in the company
order fulfillments from commercial lists (packing list and exit note will be automatically generated with this function)
refilling of consumables to production departments with minimal stock inventories (Kanban type)
improvement of the arrangement of materials in the warehouse by optimizing the taking of the most consumable items
optimizing the storage of materials based on space requirements

Hardware: 11 Honeywell 9551 with Laser Standard Range

Ease of use and rapid training of employees
Real-time querying of inventories in various warehouses
Reduction in picking times and route optimization (reduction in the number of trips)
Increased logistics staffing by 20%, instead of the expected 60%
Traceability of warehouse movements

Optimization of material picking for production
Reduced picking errors by up to 98% of cases
Storage of incoming material with automated functions on the usual or first available cell
Ability to conduct departmental inventories quickly and easily

Fai Filtri Srl

Products:

With Replica Sistemi and technology partner Citiemme Informatica, we have found solutions that have enabled us to optimize work time and reduce errors. Widely accepted by all for its flexibility and ease of use, StockSystem has brought many benefits.

Carlo Arcari

Company

Project

In December 2007, analysis of the StockSystem project began.
In March 2008 there was a Go-Live of the project.
In January 2009, RF management in the Departments was extended.

Installed products

Advantages

Information request

Fai Filtri Srl

Products:

With Replica Sistemi and technology partner Citiemme Informatica, we have found solutions that have enabled us to optimize work time and reduce errors. Widely accepted by all for its flexibility and ease of use, StockSystem has brought many benefits.

Carlo Arcari

Company

Project

In December 2007, analysis of the StockSystem project began.In March 2008 there was a Go-Live of the project.In January 2009, RF management in the Departments was extended.

Installed products

Advantages

Information request

In December 2007, analysis of the StockSystem project began.
In March 2008 there was a Go-Live of the project.
In January 2009, RF management in the Departments was extended.