Stellantis, a global leader in the automotive industry, is known for its iconic portfolio of brands, including the likes of Jeep, Alfa Romeo, and Fiat. As part of their commitment to supporting their dealer network and accommodating future growth, Stellantis undertook a significant warehouse relocation project, transitioning from a 12,000 sqm facility in Port Melbourne to a 14,000 sqm site, with a much higher roof height, in Mickleham. Safer Storage Systems (SSS) was entrusted to deliver the new storage solution.
Project Overview
With the end of their existing lease fast approaching, Stellantis needed to implement a storage solution at the new Mickleham facility as efficiently as possible.
SSS took a strategic approach to the warehouse design, considering the customer’s varied product profiles, warehouse column positions and fire safety requirements, as well as incorporating adequate staging areas and scalable storage solutions.
SSS were able to swiftly develop a customised warehouse storage layout that addressed Stellantis’ unique operational needs and commence production of materials immediately, ensuring the project could be delivered to the strict schedule.
The Solution
“The design was key – it really focused on improving the flow of the warehouse. It’s going to give us greater opportunity and efficiency in our operations.” – Mark Stefanile, Stellantis Senior Manager – Parts Inventory & Warehouse | Aftersales
Pallet Racking
Stellantis opted for Silverline® pallet racking due to its superior strength and durability. Manufactured from high-grade, high-tensile steel, Silverline racking provides added peace of mind regarding workplace safety and product longevity.
With SSS’s local manufacturing capabilities, the racking solution was custom-built to meet Stellantis’ immediate needs and future growth plans, all while meeting tight deadlines for material delivery and construction.
The pallet racking solution provided over 14,000 pallet locations, ensuring ample storage for Stellantis’ diverse inventory, including oversized products and custom pick levels.
Opting for Australian-made Silverline® Pallet Racking has saved over 39 tonnes CO2 from being released into the atmosphere! It would take 1,953 mature trees to offset this CO2 over 1 year.
Mezzanine System
A key aspect of the storage solution was the addition of a structural mezzanine, which created 36,000 storage locations for small parts. The mezzanine was carefully designed to meet strict fire safety codes while allowing for efficient workflows within the warehouse.
Inbound and Outbound Areas
SSS designed the warehouse layout to facilitate smooth inbound and outbound processes, which are crucial for Stellantis’ operations. By ensuring ample floor space in these areas, the layout improved operational efficiency and ensured seamless movement of products. This was particularly important for the handling of diverse product sizes, essential for an automation-focused business like Stellantis.
Fire Safety
Fire safety was a top priority throughout the project. SSS worked closely with fire engineers to ensure all necessary safety measures were in place. This included the installation of in-rack sprinklers and compliance with fire safety regulations to protect both personnel and inventory.
Scalable Design
SSS’s design approach focused on creating a scalable solution. By customising the storage systems around Stellantis’ current operational needs and anticipating future growth, SSS provided a solution that is scalable and adaptable. The durable Silverline® racking, engineered for longevity, ensures Stellantis can grow their operations without requiring significant infrastructure changes.
Creating a Brighter Warehouse
The new LED lighting technology, combined with the brightness of Silverline® racking, reduced the need for excessive lighting and created a vibrant, more energy-efficient warehouse environment.
Results
The completed warehouse in Mickleham now boasts over 14,000 pallet locations and 36,000 storage locations through the mezzanine, ensuring Stellantis has the storage capacity to support their growing operations. The expansion and redesign have positioned Stellantis to better support their dealer network and accommodate further growth, with a warehouse layout that is built for the long term.
All elements of the project met Australian safety codes and certification requirements, including fire engineering and building permits. The ability to deliver a high-quality storage solution within a compressed schedule, ensured Stellantis could continue operations with limited disruption.
“It has been great to work with SSS to deliver this project. The experience has been amazing, the flexibility and adaptability to the many changes we’ve had to go through in this project to deliver. The main benefit of local manufacturing, local product, and the short lead time that you’ve been able to achieve to deliver this project has been a big positive for us.”
– Mark Stefanile, Stellantis Senior Manager – Parts Inventory & Warehouse | Aftersales
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