Vekoma doubles warehouse productivity with automated vertical storage

Vekoma is a global manufacturer of steel roller coasters, supplying complex, made-to-order systems to theme parks worldwide. Rapid business growth led the company to invest in a new production facility, including a warehouse designed to integrate closely with assembly and quality control operations.

The objective was to increase storage capacity, improve picking efficiency and reduce errors, while ensuring the warehouse could scale alongside production volumes.

Manual picking constrained efficiency and accuracy
In Vekoma’s previous warehouse, manual storage and pallet-based handling resulted in long walking distances and time-consuming searches. Small components were often stored together on pallets, making them difficult to locate and increasing the risk of picking errors.

According to warehouse management, these inefficiencies directly affected productivity and created delays in downstream assembly processes. Reducing search time and improving picking accuracy became critical requirements for the new warehouse design.

Implementing a zone-based automated storage concept
To address these challenges, Vekoma adopted a smart warehouse concept structured into three zones, one of which was fully equipped with automated vertical storage systems from Kardex.

The solution included upgrading two existing vertical lift units and installing six additional systems, creating a total of 45,000 storage locations. This configuration allowed high-density storage of components while keeping frequently accessed parts close to assembly and inspection areas.




Automation streamlines picking operations
The automated picking process significantly changed day-to-day warehouse operations. When an order is released, the correct storage tray is automatically presented to the operator. A display indicates the required quantity, and a laser pointer highlights the exact bin location.

This guided picking approach has reduced search time and minimized picking errors. Within three months of commissioning, Vekoma reported a doubling of warehouse productivity compared to the previous manual setup.

Space savings and operational reliability
By using vertical storage, Vekoma avoided the need to add an additional floor to the new facility, resulting in measurable construction cost savings. High system availability was also a deciding factor. Over a ten-year period of operating similar equipment, downtime amounted to only 30 minutes, supporting continuous production flow.

Supporting scalable and error-free logistics
The automated storage solution now forms a central element of Vekoma’s internal logistics strategy. By increasing picking speed, improving accuracy and optimizing space utilization, the warehouse is better aligned with the requirements of complex, high-precision manufacturing.

The project demonstrates how targeted warehouse automation can directly support production efficiency and quality, particularly in environments where a large number of individual components must be handled reliably and at scale.