Sheet metal storage has long been the overlooked bottleneck in fabrication operations. Raw materials occupy valuable floor space, require dangerous manual retrieval, and create delays when the required gauge or alloy is buried under heavier plates. Traditional cantilever racks or vertical storage towers still rely on forklifts or overhead cranes to retrieve individual sheets—a slow, labor-intensive, and risky process. Herochu’s Smart Sheet Metal Storage and Retrieval System transforms this chronic challenge into a competitive advantage through intelligent automation, real-time inventory visibility, and seamless production integration.
The Intelligence Layer: WMS/WCS Integration
At the heart of Herochu’s smart storage system lies a sophisticated warehouse management and control architecture that transforms passive storage into active inventory intelligence. The system employs a 15-inch touchscreen interface integrated with Siemens PLC controls, providing operators with real-time visibility into every sheet stored in the system.
This intelligence layer delivers several critical capabilities:
- Inventory visualization – Every sheet is tracked by material type, gauge, dimensions, and location within the storage tower, eliminating the guesswork that plagues manual storage systems.
- Data tracking – Complete audit trails document material receipts, retrievals, and consumption, supporting quality control and production planning.
- Remote access – Inventory data can be viewed remotely, enabling production planners to verify material availability without visiting the shop floor.
- First-in-first-out material flow – Internal flow aids and anti-bridging devices ensure FIFO material movement, preventing material sticking and caking that can occur with prolonged storage.
The WMS/WCS integration extends beyond simple inventory tracking. The system communicates natively with ERP and MES layers, enabling automated material reservations, production scheduling based on available inventory, and real-time consumption reporting.
Automated Retrieval and Feeding
The retrieval mechanism of Herochu’s smart storage system represents a fundamental departure from conventional approaches. Instead of relying on forklift operators to navigate aisles and manually extract sheets, the system employs an intelligent three-axis retrieval robot that operates with precision and consistency.
When a production order requires a specific material, the WCS calculates the optimal retrieval path and dispatches the manipulator to extract the correct sheet. The system handles sheets up to 6000×2500 mm in dimension and up to 500 kg in weight, with loading arm horizontal speeds of 10 to 30 meters per minute and lifting speeds of 5 to 10 meters per minute.
The retrieval process incorporates several advanced features:
- Automated sheet separation – The system separates individual sheets from bundles without damaging surface finishes or creating edge burrs.
- Precision positioning – Sheets are delivered to the loading station with exact positioning, eliminating manual alignment steps.
- Multi-machine synchronization – The system can feed multiple laser cutting machines simultaneously, supporting complex production workflows.
Unattended Operation and Lights-Out Production
One of the most compelling value propositions of Herochu’s Smart Sheet Metal Storage and Retrieval System is its enablement of unattended operation. The system automatically connects with laser cutters, presses, and other downstream equipment, enabling night-shift unmanned production.
This capability transforms the economics of fabrication operations. Machines that previously sat idle during off-hours can now run continuously, increasing machine utilization by up to 100%. The storage and retrieval system handles material provisioning throughout the night, ensuring that laser cutters never starve for material and that finished parts are properly staged for morning shift pickup.
The system’s reliability for unattended operation is supported by robust engineering: collision prevention mechanisms, drop prevention design, and comprehensive diagnostics that alert maintenance personnel to potential issues before they cause downtime.
Space Efficiency and Storage Density
Floor space in fabrication facilities comes at a premium, and Herochu’s smart storage system addresses this reality through vertical, tower-type design. The system saves up to 85% of floor space compared to flat stacking, with a single tower capable of storing dozens of tons of material. Each storage tower can accommodate 8 to 15 levels, with clear space between layers customizable to material thickness requirements.
The space savings translate directly into operational benefits. Floor space reclaimed from storage can be repurposed for additional production equipment, value-added operations, or future expansion. Herochu’s tower-type vertical design consolidates dozens of storage positions into a compact, height-optimized structure, eliminating the sprawling footprint of traditional racking.
Scalability and Modular Expansion
Fabrication businesses grow, and Herochu’s smart storage system grows with them. The modular design supports single-tower, double-tower, or multi-tower configurations, with adjustable storage height that allows easy expansion and upgrade as production needs grow.
This scalability extends to the control system as well. Additional storage towers can be integrated into the existing WMS/WCS infrastructure, maintaining unified inventory visibility and control across the entire storage footprint. The result is a storage solution that adapts to changing business requirements without requiring disruptive overhauls or replacements.
