Beyond the Racks: How Smart Automation Launched Lockheed Martin’s Warehouse into a New Era (with Flostor as the Navigator)

The Client: Lockheed Martin Space Systems Division

Imagine building spacecraft – components must be perfect, timelines are rigid, and every single part, no matter how small, is critical. That’s the world of Lockheed Martin Space Systems Division (SSD). They’re at the forefront of aerospace innovation, a field where precision, traceability, and security aren’t just buzzwords; they’re the bedrock of success. Handling the vast array of specialized parts needed for space exploration requires a supply chain and warehouse operation that is equally, if not more, meticulous than the engineering itself.

The Challenge

Even for a company as advanced as Lockheed Martin, the ground-level reality of moving and managing physical parts can present earthbound problems. Their material operations were facing a classic growth challenge, amplified by the sheer complexity and value of the items they handled.

Grounded by Outdated Infrastructure

Their existing setup felt less like a command center and more like a sprawling, disconnected storage facility. Materials were spread across four separate buildings, making it a logistical headache to track, retrieve, and consolidate parts for specific projects (a process known as “kitting”). The reliance on old, basic two-decker racks was inefficient, wasting valuable vertical space and making access slow and labor-intensive.

The High Stakes of Manual Processes

In the world of aerospace, an incorrectly picked part or a lapse in tracking isn’t just an inconvenience; it can have monumental consequences. Their manual and semi-manual processes struggled to keep pace with the high volume of receipts and disbursements. Maintaining pinpoint inventory accuracy – knowing exactly what they had and where – and crucial lot date control for sensitive components became increasingly difficult. This lack of control was a major impediment to efficient throughput – the speed at which materials could move through the warehouse.

Think of it like trying to manage a high-tech Formula 1 pit stop using tools and methods from a roadside garage in the 1950s. The stakes are too high, and the old ways simply couldn’t keep up with the demands of modern space systems development.

The Solution

Recognizing that their material handling needed to be as cutting-edge as the spacecraft they built, Lockheed SSD decided it was time for a complete overhaul. This wasn’t just about buying new equipment; it was about creating an intelligent, integrated system that could act as the central nervous system for their critical inventory. This is where a materials handling system integrator, like FloStor, becomes indispensable.

The Integrator as the Architect and Conductor

Imagine you’re building a complex custom building – you wouldn’t just buy lumber from one place, windows from another, and roofing from a third, then try to piece it all together yourself. You’d hire a general contractor. In the world of warehouse automation, the system integrator is that general contractor. They look at your entire operation, understand your unique needs and challenges, and then design, source, and coordinate all the different pieces of technology – the conveyors, the storage systems, the software – to work together seamlessly as one intelligent whole.

For Lockheed SSD, FloStor stepped into this role. They didn’t just sell equipment; they worked closely with Lockheed’s teams to understand their specific workflows, bottlenecks, and the critical nature of their inventory. This deep dive was the blueprint phase. Then, they acted as the conductor, bringing together various technologies and subcontractors to create a unified, high-performance system.

Orchestrating Efficiency with Integrated Technology

The core of the solution implemented by FloStor involved bringing together several key automated technologies, all orchestrated by a sophisticated control system:

• The Central Brain (Information Systems Integration): Before any physical automation, Lockheed modernized its information systems with ARMS. Flostor’s crucial role involved ensuring the new physical automation system could seamlessly “talk” to ARMS. Think of ARMS as the ultimate inventory database and task manager; the automation system is the set of automated hands and feet that execute ARMS’s commands. This real-time communication is the foundation of the system’s intelligence.

• High-Density, Automated Storage (Automated Carousels): Instead of sprawling racks, the solution incorporated sixteen automated horizontal carousels. Picture a high-tech, super-sized lazy susan or automated vending machine for parts. These carousels bring the requested items directly to the operator, dramatically reducing travel time and maximizing storage density in a smaller footprint. With a capacity for thousands of totes and tens of thousands of storage locations, they provided the high-density storage Lockheed needed.

• The Automated Workforce (Extractor/Inserter Units): To interact with the carousels and the conveyor system, robotic extractor/inserter units were installed. These automated arms precisely load and unload totes, taking over repetitive manual tasks and further increasing speed and accuracy.

• The Intelligent Highways (Line Shaft Conveyors): Line shaft conveyors were implemented to move totes efficiently throughout the facility. Unlike simple belts, these conveyors allow for zones and intelligent accumulation, meaning totes can be stopped and started at specific points, creating a controlled flow of materials to where they are needed.

• The Traffic Control System (Real-Time Controls): This is where the magic of integration truly happens. A real-time control system, interfacing with ARMS, acts like the air traffic control for the entire operation. It knows where every tote is, where it needs to go, and the most efficient way to get it there based on priorities set by ARMS. This system is robust enough to manage complex workflows and adapt to changing demands.

A System Built for Control and the Future

One of the standout features of the system is its intelligence and ease of maintenance. The control system allows Lockheed to prioritize urgent tasks, ensuring critical parts move faster. It can even dynamically reposition totes within the carousels when the system is idle, moving frequently requested items closer to the access point for even faster retrieval later.

“The system is intelligent enough to keep track of all materials in the system and deliver them to the appropriate place, based on a set of priorities,” notes David Murray, supervisor of SSD stores and material operations systems.  

The underlying technology utilizes modular, networked controllers and C language programming, providing a powerful yet maintainable platform. This design allows for flexibility and scalability, crucial for a company like Lockheed with evolving needs.

“The system is modular and will serve our needs in the future too,” adds D.J. Mac Arthur, supervisor, SSD receiving and status control.  

This forward-thinking design included the ability to easily add another level of carousels above the existing ones, leveraging the same robotic inserters – a testament to the system’s inherent scalability.

The Results

The integrated material handling system implemented by FloStor delivered transformative results for Lockheed Martin Space Systems Division, directly addressing their initial challenges and setting a new standard for their material operations.

Launching Performance and Accuracy

The consolidation into a single, automated facility, combined with the intelligent control system, dramatically improved throughput. Materials now move faster and more efficiently from receiving through inspection, storage, picking, and kitting. Crucially, inventory accuracy and lot date control saw significant gains. The real-time tracking capabilities of ARMS, linked directly to the physical movement controlled by the automation system, eliminated the guesswork and manual verification that had previously hampered operations.

Tighter Control in a High-Stakes Environment

For Lockheed, the ability to maintain tight control over their valuable and sensitive components was paramount. The integrated system provides this with a level of precision previously unattainable. Every movement is tracked, every item’s location and status are known, and priorities can be managed dynamically.

A Foundation for Future Growth

The modular and scalable nature of the FloStor-designed system means Lockheed SSD is not just equipped for today’s needs but is prepared for the future. The ease of adding capacity, as demonstrated by their plans for a second level of carousels, and the flexibility of the software ensure the system can evolve as their programs and requirements change.

By partnering with a materials handling system integrator like FloStor, Lockheed Martin Space Systems Division was able to navigate the complexities of modernizing their warehouse. FloStor provided the expertise to design a holistic solution, integrating various technologies into a single, intelligent system that not only solved their immediate problems but also positioned them for continued operational excellence in the demanding world of space exploration. They turned a fragmented, manual process into a streamlined, automated engine, proving that even in the most advanced industries, getting the basics of material flow right is fundamental to success.