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Project Delivered: Hikove's Two-tier High-density AS/RS Digitalizes Warehousing at Hymson's Jiangmen Base

Project Delivered: Hikove's Two-tier High-density AS/RS Digitalizes Warehousing at Hymson's Jiangmen Base

The automated storage and retrieval warehouse (AS/RS) built by Hikove at Phase 2 of Hymson's Jiangmen base has passed acceptance and gone into full operation. With close to 37,000 storage locations and a highly integrated software and hardware system, the project overcomes the warehousing bottleneck typical of non-standard equipment manufacturing and sets a new benchmark for intelligent material flow within the Group.

The Challenge: Non-standard Manufacturing Needs Flexible Logistics

Production at the Jiangmen base involves a huge volume of materials in many specifications. In the old flat warehouse, parts were hard to find, inventory records did not match what was on the shelves and space utilization was low. Small parts, which make up most of the volume, were picked by hand over long distances many times a day, slowing the production rhythm. Since the contract was signed in October 2025, Hikove's project team analysed the production requirements in depth and, rather than simply adding equipment, designed a total plant logistics solution combining high-density storage, semi-automated picking and digital, intelligent control.

The Solution: More Capacity from the Same Space, Robots Instead of Walking

Within the limited floor space, the team adopted an innovative two-tier rack design: a flat warehouse for cage pallets on the lower level and a tote AS/RS above it. Making full use of the vertical space, the design provides three to five times the effective storage volume of a conventional flat warehouse on the same footprint.

More than ten CTUs (case-handling robots) and several under-ride AGVs operate inside the warehouse. The CTUs handle high-frequency, high-precision tote storage and retrieval, while the AGVs move cage pallets into storage and circulate empty containers. Together with goods-to-person picking stations and a semi-automated sorting line, the system frees pickers from unproductive walking, reduces physical strain and is expected to cut labour requirements in the affected roles by more than 30%.

The Software: Beyond Fixed SKUs to Flexible Kitting

  • Intelligent scheduling and picking rules: unlike the fixed-SKU warehouses common on the market, the Jiangmen base deals with the highly complex material flows of non-standard equipment manufacturing. The system introduces kit-triggered picking, grouping materials automatically by the process requirements of each work order. When the kit completion rate reaches a set threshold, the system issues picking orders according to the process bill of materials. This enforces discipline in production planning at the source and reduces line stoppages caused by missing parts.
  • Full-stack software control: the WMS (Warehouse Management System) sets the strategy, the WCS (Warehouse Control System) coordinates the equipment and the RCS (Robot Control System) directs the robot fleet. Hot-standby servers, UPS protection and a high seismic design standard keep the system running safely around the clock.

The Results: Lean Manufacturing Driven by Real Data

Busy, orderly, unmanned and digital operation is now the daily reality:

  • Space: nearly 37,000 storage locations planned across the warehouse, meeting large-scale storage needs.
  • Throughput: the system handles thousands of inbound items and hundreds of picking orders a day; the cycle time for multi-format containers has fallen sharply and overall inbound and outbound efficiency has improved by more than 60%.
  • Accuracy: End-to-end barcode management and markedly higher inventory accuracy, making production plans far more executable.

Delivery Is Only the Beginning

The production manager at Hymson's Jiangmen base commented:

"In the old flat warehouse, finding materials took time and effort, and mismatches between records and stock often starved the production line. Since the new system went live, kit-triggered picking has forced our planning to be rigorous: whatever the line needs, the system picks in advance. Inventory accuracy has improved markedly. We have not just put an end to searching blindly for materials; our production rhythm is smoother than it has ever been."

As a key member of the Hymson Group ecosystem, Hikove combines strong system integration capability with deep experience in customized, complex applications. Hikove will continue to deepen its work in intelligent logistics and bring this proven approach to more manufacturers, empowering logistics with intelligence and driving global efficiency.