The Challenge

Valeo Vision Systems, a global leader in advanced driver assistance and automotive vision technologies, faced growing pressure on their production facility. Increasing inventory demands required a solution that could optimise their existing footprint, accelerate material handling processes, and provide seamless data integration with their core SAP ERP system for full traceability and accuracy.

The Solution

As Ireland’s exclusive Dexion distributor, Storage Systems Ltd. designed and delivered a state-of-the-art automated storage solution as part of Phase 2 of Valeo’s automation strategy. The core of the project involved the supply and installation of two Dexion Tornado Vertical Lift Machines (VLMs).

These machines were configured with Height Optimised Tornado (HOT) mode to dynamically allocate tray space, maximising storage density within a minimal footprint. The system is powered by TCPlus Warehouse Management Software, which was fully integrated into Valeo’s SAP ERP system to create a single, unified workflow for order handling and inventory management.

Implementation & Training

The installation was completed in April–May 2024. Our technical team configured the TCPlus software to communicate directly with SAP, enabling automated order processing and real-time data transfer between the systems. This direct link eliminates manual data entry and ensures live inventory accuracy.

To ensure a smooth transition and immediate productivity gains, Storage Systems Ltd. provided in-depth, onsite training for all relevant staff. Operators were trained on the machine controls (TC1200) and the ERP-linked TCPlus software. Furthermore, remote support capabilities were enabled to allow for rapid troubleshooting and minimise potential downtime.

Results & Key Benefits

The Dexion Tornado system has transformed Valeo’s intralogistics, delivering significant operational advantages:

• Vastly Increased Storage Capacity: The vertical design provides high-density storage within a minimal footprint, freeing up valuable floor space.
• Enhanced Productivity: Automated picking and put-away cycles are significantly faster than manual processes, directly supporting production line efficiency.
• Real-Time Accuracy: Full SAP integration ensures live inventory updates, drastically reducing picking errors and improving stock traceability.
• Improved Safety & Reliability: The Tornado VLMs are CE-compliant and equipped with advanced safety systems to protect both operators and goods.
• Future-Proof Scalability: The modular design of the Dexion Tornado system allows Valeo to easily expand its automated storage capabilities in line with future growth.