Case Studies | Kompress India Pvt Ltd
Case Studies
Beyond the Brief! Out of the Box!

The customer should not fit into the solution… rather the other way around! Sometimes, clients have special and unique needs that go beyond even Kompress’ expansive portfolio of solutions. That’s when Kompress’ Special Projects team takes over. Analysing the stated need and providing innovative turnkey solutions to ensure success of the assignment – however complex.

  • Pharmaceuticals

    Indore

  • Oil Industry Offshore Platform

    Mumbai

  • Medical Service

    Jaipur

  • Rittal
  • IMERYS

    West Bengal

  • Indian Navy MO

    Port Blair

  • Indian Navy MO

    Kerala

  • Pragati Aroma

    Mumbai

  • Moxcen

    Mumbai

  • Novozymes

    Patalganga

PAR Pharmaceuticals, Indore

Motorised Racking in Warehouse

Challenges / Requirement

Maximise storage space.
Ease of movement of MHE inside the storage area.
Sturdy maintenance-free system.
24/7 operations.
Palletised storage.

The material is stored on a standard pallet, and handled using a MHE for storage and retrieval. Size of pallet is defined and available vertical storage space is used. Each pallet weighs 1 ton and needs to be safely stacked and retrieved from a height of 6 m.

Solution

Kompress Motorised Racking was offered as the best solution. The entire room was divided into two storage sides countering the presence of pillars in the room. The layout ensured enough space for easy movement of men, material and MHE. The rails of the system were supported on a section of the floor. They were made flush with the floor level in a slope condition. The carriages were mounted with all necessary safety features. The superstructure was then built. The entire system was wired and integrated with a control panel. Apart from ease of storage retrieval, an appreciation of 70% in space utilisation was achieved over conventional racking in the same space. An intelligent application of product utilisation indeed!

Execution Time

The entire project was completed within 90 days.

Features

Low decibel product
Low running cost
Maintenance-free
Highly secured

ONGC Offshore (Oil Industry Offshore Platform)

Location

Offshore Platform about 80km into the sea from Mumbai shoreline.

Challenges / Requirement

It was a huge logistic challenge to transport all the material from Kompress Factory to client base (Oil Platform) situated 80km into the sea.The same could only be transported by boat and hauled up by cranes. The task became even more formidable because of choppy weather and heavy rain.

Apart from the weather and transport logistics, confined spaces, challenging work environment, safety procedures and survival and fitness certificates for workmen further heightened the daunting task. Most of the storage rooms were comparatively small with unique profile.

The entire material had to be packed in sea-worthy condition with absolutely no scope for shortage or damages.

Solution

All the various stores on the platform were identified along with their intended product storage and a suitable solution was devised.

The products supplied included Heavy Duty racking, Heavy Duty Mobile Compactors specifically made to store heavy spare parts, high value products and controls products.

Benefits

Storage space is most critical and very precious in such remote locations. Our storage solution helped drastically increase storage capacity by almost 60-65% within the same storage space.

Execution Time

6 months including inclement weather

RMSCL (Rajasthan Medical Services Corporation Ltd) Jaipur

RMSCL, Headquarters in Jaipur serves as the Government procurement entity for all medical facilities activity for the entire State of Rajasthan. Under the Mukhya Mantri NishulkDava Yojana it was decided to create medical storage warehouses across all 33 districts and various Government medical colleges in the state.

Challenges

The work was supposed to be carried out across the length and breadth of the state spanning 33 districts. The terrain weather, logistics and the challenge of completing the project within time. Interaction with various teams at the client’s end, documentation compilation and submission.

Solution

The solution proposed was long-span racking along with required material handling equipment (MHE). The layout of the racks was evolved to counter the presence of pillars and facilitate easy movement of man and material and follow all mandatory rules for medical warehouses. The supply had to confirm all the required technical norms required by the client and certified by the warehouse manager. Site verification, supply and documentation had to be accurate and to be completed within time.

Benefits

Initially before we provided the storage system and MHE, the material was randomly stored all over the floor, stacked one upon the other. This posed a huge challenge in terms of retrieval, shortage of storage space, damages, high dependences on manual labour and inefficient work environment.

The client could thus achieve almost 300% more storage due to optimal utilization of space using our long-span racking supply. Storage and retrieval time were greatly shortened, and the use of MHE helped cut down human effort drastically. All of this helped increase work force efficiency many times over. Damages and rejections of medicines were reduced to negligible levels.

Execution Time

4- 6 months night from site assessment to commissioning.

Rittal

Cantilever to keep special size of pallets

challenge

Rittal are manufacturers of industrial enclosures, electronic packaging, etc. Rittal was having a special metallic pallet of size 2.1 mtr. X 1.2 mtr. having a load capacity of 800 kg/pallet. These pallets were used to keep the unfinished goods (metallic panels) in their factory which were used during production and had to be moved to multiple locations for different jobs and assembly lines. Being a bulky product it was difficult to stack the things in a conventional racking system. Rittal was finding it difficult to store the pallets and were desperately looking for some solution.

Objective

It was difficult at first instance to store such type of system by any conventional method. To design something special was a costly affair and also time consuming. After going through 2-3 meetings we understood their requirement and suggested cantilever racking system with different sizes of bracing to accommodate the pallets.

Solution

KOMPRESS designed a cantilever storage system which were used to keep pallets instead of long items. Normally pipes, aluminium, profiles and other architectural materials are kept in a cantilever racking system but here by doing minor modifications in the size of the bracings we were able to keep the pallets instead of longer items.

Result

Here to use the vertical space we gave a cantilever rack of height six meters having arms of size 1200 mm to accommodate the pallets. The rack was having size storage levels thereby increasing the capacity six times and having an option of random pickup of materials.

IMERYS

Storage solution for a steel industry giant in Durgapur, West Bengal

challenge
  • Dense Storage

  • Storing bulky materials of variable sizes

  • Conventional storage system could not provide the required capacity asasasasas

Solution : PUSH BACK RACKING SYSTEM

Kompress examined the requirement, space and the material inflow and outflow of the warehouse. It was observed that the same type of material was keptbatchwise and they required different materials from time to time to prepare their mixture in the plant. Kompress therefore suggested two types of storage solutions: 1. Drive-in Racking and 2. PushBack Racking. The challenge with the Drive-in Racking solution was that it would require procurement of specially designed MHE for the drive-in system and in that case each row would have to be assigned for one kind of product. The advantage with the Push Back racking system was that there was no additional cost or requirement to procure new MHE, as the existing MHE could do the operation and also each level of every column could be dedicated to one type of product. So instead of one batch per row it would have 4 batches per row.

Benefits
  • The operations became simpler for MHE operators as there was a clear classification of aisle and rows.

  • Easy storage and retrieval of material lead to minimum turnaround time.

  • Extra storage capacity of more than 60% was achieved as compared to the previous conventional racking.

  • Utilization of vertical space.

Execution Time

4 months

Indian Navy MO

Storage solution for Indian Navy, Port Blair

challenge
  • Logistics along with product mix, weather and manpower was the biggest challenge.

  • An assortment of materials were required to be stored at the newly constructed warehouse on a small isolated island which was 1350 km away from the mainland.

  • Space was a major constraint and it had to be optimized keeping in mind the ease of storage and retrieval along with the value of the stored items.

Solution : HEAVY DUTY STORAGE SYSTEM

Kompress Heavy Duty Storage System provided the ideal solution to overcome the constraints and fulfil all the storage needs. Warehouse which would have offered only 2000 sqft of storage space using conventional storage methods now offered about 3800 sqft of storage space along with providing all the conveniences of a modern storage system.

Benefits
  • Space optimization.

  • All steel construction wasdust resistant,termite resistant andeasy to use.

  • Scientific storage methods withseparate space for every store, longer shelf life and stock identification.

Execution Time

6 months including inclement weather.

Indian Navy MO

Customized storage solution for Indian Navy, Kochi, Kerala

challenge
  • 3000 SKU’s of varied shape, sizes and weights to be stored in one area.

  • High energy consumption as the client had to keep the lights on through the day

  • Due to lack of organization the warehouse was in a mess and all the materials were lying on the ground with entire vertical space being wasted.

Solution : ENERGY EFFICIENT COMPACTOR WITH DRAWER ARRANGEMENT

After thorough examination and on-site inspection of material movement, storage and retrieval frequency and product knowledge, we observed:

  • Though there were 3000 SKU’s, the quantity was not big but the items had to be stored in a single location

  • The size variation was too high.

  • All parts were identified by a special number and that was already fed in the internal data bank.

On the basis of our observation, we provided a very unique and customized solution to the client. Compactors with Drawers where total 10 loading/storage levels were createdand, in each face-outbottom 5 were drawers and top 5 were shelving. All the drawers were of variable size ranging from 50mm, 100mm, 150mm, 200mm and 250mm height.The drawers of height 50mm and 100mm were specially designed to store small parts like washers, nuts, bolts etc. and a mesh was provided which was adjustable depending upon the size of SKU. Therefore, multiple SKU’s couls be stored in the same place and could be identified with indexing provided.

In order to use the vertical space, the height was elevated up to 12ft (3600mm) where top levels were identified to store the SKUs that were rarely retrieved.

Now addressing the elephant in the room, the major challenge of energy consumption… We devised a unique solution wherein the mobile compactors were integrated with limit switch and lights. They work in such a way that only the light of the aisle space that has been opened will be in ON position and rest all will be OFF. This reduced the energy consumption as the entire warehouse did not have to be lit throughout the day.

Benefits
  • Reduced energy consumption by almost 1/5th

  • After completion they were able to keep all the SKU’s as per the scientific group classification.

  • Able to easily store, identify and retrieve as all the drawers, shelves and compactors bay were indexed and the data of all SKU’s location were stored in the IT Data bank system.

  • Operation became easy, effective and clutter-free.

Pragati Aroma

Mumbai

challenge

The client is in the business of manufacturing high-value perfumes. Typically, its products are stored in bottles of sizes ranging from 100 ml to 2000 ml. The challenge lay in storing all the bottles, big and small in one place, yet making storage and retrieval easy, and all of this while maximising capacity.

The biggest challenge lay in identification and retrieval. A huge challenge because both the bottle and contents are very expensive. They have to be imperatively stored upright and, irrespective of their shape or dimensions, have to provide full frontage for instant label recognition. Given all the issues, stability of the stored bottles was always at risk.

Solution

Thebrief demanded that both, the final design and solution, had to be absolutely unique. Carefully analysing the need, Kompress decided on a compactor with a step-style of shelves. Each shelf would hold 2-3 rows of bottle, and each subsequent shelf on the next level would similarly hold 2-3 rows… and so on. The entire system represented a step-ladder format which made identification easier. Every step was fitted with bottle stoppers to prevent the bottles from toppling over whenever the compactor was moved. The storage capacity increased three times.

The design was indeed very unique – unseen anywhere else. Equally unique was the fact that the site of installation was well beyond Kompress’ regular territory – it was in Sharjah, in the Middle East. Yet again, Kompress overcame all odds to design, develop, transport and help assemble the entire system offshore, to the client’s extreme satisfaction.

Execution Time

Two months.

Moxcen (Defence Sector)

Mumbai

challenge

The Indian Navy has its ships out on the high seas, but each of those need to regularly dock at port in order to replenish supplies. The regular practice for this is an assigned sailor, on the instruction of the captain, going ashore and picking up the list of supplies against a debit-card type of instrument, from a Naval approved store.

Needless to say, these stores would be crowded with a plethora of products – over 1000 SKUs of each, with many multiples in inventory – which made display, storage and retrieval a small nightmare. Kompress were invited to conceptualise, commission and deliver, exclusively for the Navy, a mall-like store that would eliminate the said problems.

The challenge was rendered a bit more complex because the Indian Navy runs these stores via its exclusive software; hence any software designed by Kompress would literally have to plug and play into the existing architecture.

Solution

Kompress roped in its in-house software arm, CRIBS, who successfully designed the module that seamlessly integrated with the existing mother software, without any glitches right from Day One. Meanwhile, Kompress’ designing team were busy working out the storage architecture that, in consonance with the software, would make the entire store-functioning a breeze.

Conventionally, malls have static racking on which a variety of material – from small pieces to large, bulky units – are placed or stored. Keeping this in mind, Kompress switched the format to a combination of Long Span and Mobile Racking, which resulted in a saving of space and a sense of openness and airiness; but most of all the flexibility of storing anything and everything in a limited space. It made identification and retrieval very easy too.

It was virtually a turnkey solution with trolleys, checking, check-out and billing counters also part of Kompress’ offering. Along with the software, all compatible hardware such as RFID readers was also provided. The entire system allowed the store to comprehensively manage every bit of inventory data, as well as maintain a log of every customer who had ever shopped over the years.

Execution Time

Two months.

Novozymes (Pharma Sector- Change part Storage)

Patalganga

challenge

The client is a world leader in biological solutions, with a strong portfolio in enzymes for the food, beverages and household care industries. The dual challenge that confronted Kompress was that some of the required material could only be stored in a stainless steel base, and the volume of storage was high as compared to the available space. This was further complicated by varying dimensions and sizes of the to-be-stored material.

The only way out was to develop a unique compactor completely in SS304 grade of steel. This itself represented a new challenge because it was never done before – hence, special machinery and a special procedure would have to be followed in both manufacturing and installation. Cost was another huge issue, because SS304 is expensive material, and yet, the final product had to be delivered within a specified budget.

Solution

The problem was put forth to Kompress’ R&D department. After minutely scrutinising the requirement and challenges, and discussing the issue threadbare, followed by a detailed technical analysis, a manufacturing and installation protocol was defined and religiously followed.

Intelligently calibrating the manufacturing process, the design was intricately modified. The compactor was uniquely built to withstand loads of up to 100 kgs per shelf, which worked out to a total load of 7-8 tons per base. The colossal weight rendered moving the compactor units a huge challenge, but Kompress’ ingenuity won out again, much to the delight and approval of the client.

The project ensured that the client had enough capacity to fulfil their entire storage requirement under one roof – saving them the inconvenience of scattering the same over different locations. The entire design and execution also met the norms laid down by the Audit of Food and Beverages Industry.

Execution Time

3 months.

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