An agile and efficient warehouse flow management innovative system
Gigacer needed to optimize warehouse flows, implement real-time operations control, and make picking activities more efficient.
A leading player in Italian ceramics
Gigacer, founded in 2007 and based in Faenza, is an Italian company specializing in the production of large “Made in Italy” porcelain stoneware slabs for architecture, interiors, and exteriors, with sizes up to 120×250. The company stands out for its strong focus on aesthetic and technical quality, using natural raw materials, “Continua” production processes, and tailor-made services for cutting, polishing, and adaptation to the project, while respecting environmental sustainability.
€20 million
in turnover
35,000 m²
of warehouse space
120×250 cm
maximum slab size
Customer needs
35,000 m² of warehouse space to be optimized
Gigacer needed to optimize warehouse flows, implement real-time operations control, and make picking activities more efficient at its production and logistics site in Faenza, relying on a Forklift Guidance System (FGS) that could function correctly in three indoor areas and one outdoor area, covering a total surface area of 35,000 m².
This was no easy task, especially given the indoor/outdoor positioning technologies available on the market, which often require invasive work on the structure and, consequently, involve high costs.
On.Plant solution
An agile and efficient warehouse flow management system
The activation of On.Plant's WMS and RTLS has made it possible to digitally manage all warehouse flows, including those exchanged with production.
In addition, thanks to Dragonfly, an innovative Real-Time Positioning technology developed by Onit, an FGS (Forklift Guidance System) has been activated for the five forklifts operating in the picking bays.
Using computer vision and essential, minimally invasive forklift hardware, Dragonfly technology has enabled Gigacer to achieve a real-time forklift positioning system with centimeter precision, both outdoors and indoors.
The FGS enabled by Dragonfly has allowed Gigacer to make its warehouse activities more efficient.
The system tracks the position of pallets in real time thanks to auto-identification features and, by combining information on the position and orientation of the forklift with the status of the forks, identifies the xyz position where each pallet is stored or picked up.
The forklift operator only needs to consult the on-board display, which provides a 3D representation of the warehouse and directions for quickly reaching the picking and depositing points.
FGS view while stocking a pallet in a correct place
Achievements
Gigacer ceramics ready to be shipped all over the world
This solution has enabled the implementation of an intelligent mission assignment system, optimizing forklift utilization and supporting drivers in guided picking activities.
All this is under the constant control of the operations center, which, through a digital twin of the plant, can now know the position of each forklift and monitor the progress of activities minute by minute.
3D Digital Twin indoor & outdoor warehouse
