New AutoStore implementation at Solera

Solera, one of the largest manufacturers of low-voltage electrical equipment with more than 50 years of experience, has taken a decisive step towards innovation in its logistics operations. Manufacturer, designer and marketer of more than 2,000 references, Solera offers its distributors a complete range of solutions for electrical installation. In its quest for optimization, the company has relied on Smartlog for the automation and digitization of the order picking process at its plant in Paterna, Valencia.

Solera faced the challenge of improving order management efficiency for its medium consumption lines. The main objective was to reduce operation times and maximize available storage space, ensuring accurate inventory control and adaptability to demand growth, without the need to physically expand the facility. Additionally, the upcoming migration of their ERP from AS400 to SAP represented a challenge that required a smooth and uninterrupted transition, maintaining operations 16 hours a day with high productivity levels.

After analyzing several options, Solera has decided to implement Smartlog’s AutoStore technology, which will be operational as of January 2025. The system consists of a grid with a capacity of 5,326 330 mm. bins and 5 high-speed robots, which will manage the order-to-order picking of lines with an average consumption of up to 25 liters. It includes two versatile carrousel stations, which allow both infeed and outfeed, providing great operational flexibility. This technology will be fully integrated with the AS400 system and is prepared for future migration to SAP, given the flexibility and interoperability of Galys, our own warehouse management software.

Thanks to its commitment to Smartlog, Solera will be able to increase storage density, maximizing the use of available space with the capacity to manage up to 5,326 bins. Likewise, order picking accuracy will improve significantly, reducing errors and ensuring greater customer satisfaction. Automation will optimize inventory management, speeding up delivery times and increasing productivity by automating repetitive tasks, freeing employees to focus on more value-added activities.

The AutoStore system will also provide operational flexibility to manage both inflows and outflows from either of the two carrousel stations. This scalable system is designed to adapt to Solera’s future needs, ensuring a smooth transition between the AS400 and SAP systems and providing a significant increase in operational efficiency, with continuous operation 16 hours a day. In addition, energy consumption will be reduced thanks to the low power consumption of the robots, which will also generate considerable savings in operating costs.

In line with its commitment to quality, safety and social responsibility, Solera will also realize significant ergonomic benefits for its employees, improving working conditions and reducing the physical burden of repetitive tasks.

With this implementation, Solera reaffirms its commitment to operational excellence and technological innovation. The company is now better prepared to face the challenges of the future and to continue growing in an increasingly demanding market.