Case Study

Autostore System Installation

Founded in 1917 Birmingham, Mayflex has come a long way from its early days selling Swan Kettles and Switchgear Cables.

Today, Mayflex is a leading provider of copper and fibre cabling, racks, Ethernet switches, wireless and IP Security solutions.

Over the last two decades, the company has sharpened its focus on cutting-edge technology to stay ahead in the fast-evolving electrical and networking sectors.

With a passionate team of 280 associates, Mayflex achieved impressive sales of £165.5 million in 2023. Operating a massive inventory of £18 million, Mayflex processes over 2,300 orders daily, fulfilling 98% of them directly from stock.

Its UK headquarters in Birmingham house two large, state-of-the-art warehouses, with 12,000 pallet locations and facilities for cabinet configuration and specialised support services. Along with its UK operations, Mayflex has expanded globally, with a presence in Dubai to serve Middle Eastern markets.

Through its Excel brand, the company continues to distribute high-quality products to markets across the world.

Birmingham, West Midlands
2024
Autostore system
Automotive
Autostore system
Autostore system
Autostore system
Autostore system
Autostore system

With Autostore and the introduction of the 14 Maybot robots, we can enhance our service levels further. The whole process will be far quicker to process orders, which will be particularly useful for customers ordering at the trade counter or for same day despatch requirements.

Solutions

To remain at the forefront of customer satisfaction, Mayflex made a substantial investment in 2024 by upgrading its Central Distribution Centre (CDC) in Birmingham with an advanced Autostore system.

This strategic decision not only reflects Mayflex’s commitment to providing exceptional service but also aligns with the increasing trend of automation within distribution centres across the industry.

The implementation of the Autostore system is designed to significantly enhance operational efficiency while minimising errors. By automating key processes, Mayflex can:

  • Streamline inventory management
  • Accelerate order processing
  • Ensure faster deliveries.
  • Provide greater accuracy in order fulfilment
  • Reduce lead times
  • Deliver a superior service that meets and exceeds customer expectations.

The shift toward automation, marked by the Autostore system, not only positions Mayflex as a leader in the distribution sector but also reinforces its dedication to continuous improvement and innovation in meeting the evolving needs of its clients.

Autostore system

Results

The electrical installation of the Autostore system, implemented by Hills Electrical Group, was completed on time and within budget. The facility now boasts 14 advanced R5 RedLine robots, affectionately named ‘Maybots,’ working tirelessly to manage over 17,500 storage locations.

These autonomous robots are supported by four ergonomic workstations and a dedicated service mezzanine.

Sam Baldwin, Mayflex’s Operations & Services Director, shared his enthusiasm for the new technology: “With Autostore and the introduction of the 14 Maybot robots, we can enhance our service levels further. The whole process will be far quicker to process orders, which will be particularly useful for customers ordering at the trade counter or for same day despatch requirements.”

Baldwin highlighted how the integration of the Autostore system will not only boost accuracy but also streamline order processing. The system’s design ensures that only the required product is delivered, with each item being scanned by sophisticated Cognex scanners to guarantee accuracy. This automation drastically speeds up the order fulfilment process, proving particularly useful for same-day dispatches and trade counter orders.

Furthermore, Mayflex has embedded sustainability into the core of its automation strategy. The Autostore system automatically selects the smallest possible outer box for each order, reducing waste and minimising the need for void fillers. In an innovative step towards eco-friendly practices, Mayflex has also introduced crash-lock boxes, which eliminate the need for tape and are easier for customers to open.

As businesses across the globe shift toward automation in distribution centres, Mayflex stands as a leading example of how Autostore system technology can transform operations. Their investment in the Autostore system demonstrates its commitment to staying ahead of the curve, prioritising customer satisfaction and sustainability.

Autostore system

Invest in State-of-the-Art Autostore Systems

Hills Electrical Group, founded in 2007 in the Midlands by Managing Director Adam Hill, has become a leading provider of warehouse automation and Autostore systems. Our mission is to help businesses optimise operations, enhance productivity, and drive profitability through innovative automation solutions.

When you choose Hills Electrical Group, you’re not just selecting a top-tier electrical installation partner; you’re revolutionising the way your projects are delivered for success.

Our team of NICEIC approved engineers, technicians, and project managers are proficient in electrical installation, and prepared to work closely with you to design and implement a solution that positions you for future growth and success. Get in touch today by calling 01384 671660

What Our Team Provided

Autostore Installation
Fourteen R5 RedLine Robots
Four Ergonomic Workstations
Service Mezzanine
Testing
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