Smart Manufacturing Case in Window and Door Production Lines | More Than a Cabinet — It’s the Bridge Between Logistics and Production Systems!
“Our material warehouse used to be far from the production line. When production sped up, locating and replenishing materials couldn’t keep up with the pace. Now, with the Modula intelligent vertical lift module installed right next to the line, materials can be retrieved in seconds, production never stops, and the entire workflow is far more stable!”
— Production line staff at LEAD CNC
Customer Profile
Founded in 2007, Shandong LEAD CNC Machinery Co., Ltd. is a national high-tech enterprise specializing in the design, R&D, manufacturing, and sales of intelligent aluminum door and window production lines.
The company has ranked No.1 in national sales of home door and window intelligent production lines for five consecutive years.
With more than 150 national patents, LEAD CNC is dedicated to driving the industry’s transformation toward high efficiency, automation, and intelligence, and to building an industry-leading “dark factory.”
Customer Challenges
As a leading enterprise in China’s intelligent door and window manufacturing industry, LEAD CNC’s production workshops have long been highly automated.
However, as order volumes increased and product models diversified, line-side material management became a major bottleneck:
- Limited preparation space
- Low material retrieval efficiency
- Unstable replenishment cycles
- Disorganized inventory information
This often resulted in the awkward situation where “machines are waiting while people are still searching for materials.”
They gradually realized that what was affecting production efficiency wasn’t the machines themselves — it was delays within the logistics supply chain.
To truly improve manufacturing efficiency, material management had to undergo systematic and intelligent upgrading.
Why Modula?
Because it doesn’t just store — it feeds materials in sync with the production rhythm.
During the project planning stage, LEAD CNC wasn’t simply looking for a traditional storage system.
They wanted to establish a “smart line-side material replenishment center” — one that would be close to the production line, respond quickly, and integrate seamlessly with the production system.
That is exactly where Modula’s intelligent vertical lift module (VLM) excels.
Unlike conventional warehouse equipment, Modula systems are not confined to warehouses.
They support line-side applications, enabling high-frequency material retrieval and software-driven inventory scheduling.
This allows Modula to be embedded directly within the production line, forming a localized logistics center that ensures materials arrive exactly when needed.
After on-site assessment and solution discussions, the Modula team, together with its distributor Qingdao Dingli Industrial Equipment Co., Ltd., finalized the plan:
Move warehouse functions closer to the line — bring materials to the production rhythm and let logistics flow in sync with manufacturing.
Efficiency Boost: Reshaping Material Flow
The real transformation lies in how operations are performed.
The Modula VLM was installed at the core of the production area, dedicated to managing high-frequency, small-sized, and diverse parts such as fasteners, window connectors, electrical components, and tooling fixtures.
These items, which were once scattered across various line-side racks, are now centrally managed and easily retrievable.
Previously, operators had to walk between multiple racks, relying on memory to find materials — time-consuming and error-prone.
Now, they simply enter the tray number on the touchscreen, and the system automatically brings the corresponding tray to the access window.
This shift transforms the traditional “man-to-goods” model into a modern “goods-to-man” approach.
The impact has been remarkable:
- Material retrieval speed has increased significantly.
- Error rates have dropped sharply.
- Labor is saved.
- Most importantly, replenishment becomes predictable, replacing the previous chaotic, reactive process.
After implementation, LEAD CNC’s workshop environment changed dramatically — line-side areas became tidy and organized, previously cluttered spaces were freed up, and the production area became safer and smoother.
A Replicable Line-Side Logistics Model
The success of the Modula VLM solution not only resolved LEAD CNC’s material management issues but also gave the company a new production capability — the ability to integrate line-side logistics systems.
LEAD CNC’s production manager summarized it perfectly:
“This isn’t just a VLM — it’s the bridge between our logistics and production systems.”
In the future, this model — automated production lines combined with intelligent line-side replenishment — will become a key part of LEAD CNC’s turnkey smart factory solutions.
Application Video
Final Thoughts
In intelligent manufacturing, competition isn’t only about speed — it’s about coordination.
The true value of Modula lies not just in the VLM itself, but in the systemic capabilitiesit brings — scalable, replicable, and integrated.
It helps factories evolve from isolated automation points to coordinated, system-level automation, building a standardized, smart line-side replenishment framework that lays the foundation for future expansion and digitalization.
