How a Custom AS/RS Solution Improves Warehouse Efficiency in Cable Manufacturing

ndustry Challenges in Cable Manufacturing Warehousing

Driven by growing demand from the new energy, power transmission, and infrastructure sectors, cable manufacturers are managing an increasing number of SKUs, reel sizes, and customized orders. Traditional warehouse operations often struggle to keep pace with these requirements.

Unlike standardized products, cable reels vary significantly in diameter, weight, and storage requirements. As production volumes increase, many manufacturers face challenges such as low storage density, inefficient material handling, inventory inaccuracies, and rising labor costs.

These warehouse bottlenecks can directly affect production efficiency, order fulfillment, and long-term business growth.

Project Background

A leading cable manufacturer was experiencing rapid business expansion and increasing warehouse pressure. The factory handled thousands of cable reels of different specifications while supporting high-volume production and customer-specific orders.

Its existing warehouse relied heavily on forklifts, manual inventory management, and conventional storage racks. As order volumes increased, warehouse operations became a major constraint on production capacity and logistics efficiency.

The company needed a Smart Warehouse Solution capable of increasing storage capacity, improving material flow, and supporting future growth.

DELIECN Smart Warehouse Solution

To address these challenges, DELIECN designed a customized AS/RS Warehouse Automation solution specifically for cable reel storage and intralogistics management.

High-Density AS/RS for Cable Reel Storage

DELIECN implemented a double-deep AS/RS system capable of storing both cable reels and pallets within the same warehouse environment.

Key benefits included:

• More than 2,800 storage locations
• High-density vertical storage
• Improved space utilization
• Automated inbound and outbound operations

The system maximized existing warehouse space without requiring facility expansion.

Automated Material Handling and Production Integration

To connect production areas with warehouse operations, DELIECN deployed:

• Pallet Lifters
• Automated conveyor systems
• AGVs
• Intelligent transfer stations

This created a seamless flow of materials between production, storage, and shipping areas while eliminating manual transportation bottlenecks.

WMS and WCS Integration

DELIECN self-developed WMS and WCS platforms provided centralized control of inventory and equipment operations.

The system enabled:

• Real-time inventory visibility
• Intelligent storage allocation
• Automated task scheduling
• Equipment monitoring
• Integration with ERP and MES systems

This transformed warehouse operations into a fully digital and data-driven process.

Project Results

Following implementation, the manufacturer achieved measurable improvements across warehouse operations.

Why Smart Warehousing Matters for Cable Manufacturers

As cable manufacturing becomes increasingly complex, warehouse efficiency plays a critical role in maintaining competitiveness.

Smart Warehouse Systems help manufacturers:

• Increase storage density
• Improve inventory accuracy
• Reduce operating costs
• Accelerate order fulfillment
• Support customized production
• Enable digital transformation

Rather than functioning as isolated storage facilities, modern warehouses have become integrated logistics hubs that directly support production performance and customer satisfaction.

Conclusion

Warehouse efficiency is becoming a key competitive factor in the cable manufacturing industry. Traditional storage and handling methods can no longer support the growing demand for flexibility, accuracy, and productivity.

By combining high-density AS/RS technology, automated material handling, and intelligent software platforms, DELIECN helps cable manufacturers build scalable Warehouse Automation Systems that improve operational efficiency, support future growth, and strengthen lon