In this enlightening case study, discover how a supplier to the demanding aerospace and aviation sectors overcome throughput and productivity constraints to advance its operational performance through intelligent digital solutions.
Across modern manufacturing and distribution environments, process technology is playing an increasingly central role in driving efficiency, resilience and performance. As customer expectations continue to rise, particularly around speed, accuracy and transparency, organisations are being pushed to rethink traditional operating models and adopt technology-driven solutions that deliver measurable results. Silmid, a leading supplier to the aerospace and aviation sectors, offers a strong example of how process optimisation, automation and digitalisation can transform operations while maintaining a people-first mindset.
Silmid’s value proposition centres on the on-demand supply of small-volume orders through its full-service B2B ecommerce platform. A long-time partner to major suppliers such as PPG Aerospace, Shell Aviation, and 3M Aerospace, the company sources from more than 400 vendors to meet highly specialised customer requirements. From its Coleshill facility, Silmid manages over 5,000 SKUs and processes approximately 60,000 orders annually, serving customers worldwide.
In the aerospace and aviation sectors, speed of delivery and product quality are non-negotiable. Tight cut-off times for same-day shipping and consistently high accuracy standards are baseline expectations in a demanding, highly regulated environment. These service levels have helped position Silmid as a trusted partner to its customers. However, as order volumes increased and growth targets surpassed 25% annually, maintaining these standards became increasingly difficult without changes to underlying processes and technologies.
Like many fast-growing organisations, Silmid began to experience throughput and productivity constraints. Process inefficiencies, limited real-time visibility and longer fulfilment cycles began to impact key performance indicators. These challenges were further compounded by the company’s diverse and specialised product mix, which required unique packing workflows and limited the effectiveness of traditional wave-based batching and picking approaches.
To address these challenges, Silmid sought a more intelligent, technology-led approach to process optimisation and partnered with Lucas Systems. With more than 25 years of experience applying voice and AI-driven optimisation technologies in warehouse and distribution environments, Lucas Systems brought a strong focus on operational excellence, alongside deep expertise in advanced picking, staging and packing processes.
Before implementation, Silmid was managing significant order backlogs, often in the range of 300 to 400 orders, and relying heavily on overtime to meet demand. Following deployment of the new solution, fulfilment performance improved dramatically, enabling next-day delivery as a standard outcome rather than an exception. This marked a major improvement in operational efficiency and demonstrated the impact of strategically applied digital process control.
At the core of the solution is Jennifer™, Lucas Systems’ warehouse AI engine and voice-enabled orchestration platform. Rather than relying on static workflows or fixed waves, the system enables continuous optimisation across picking, staging and packing activities. Silmid implemented a multi-modal picking strategy that combines voice direction with RF scanning, improving accuracy while increasing worker productivity. Continuous order prioritisation ensures urgent and high-value orders are addressed immediately, without the delays typically associated with batch processing.
Intelligent, on-demand batching dynamically balances workloads across labour and equipment, while optimised pick paths reduce unnecessary travel and handling time. These capabilities are supported by a real-time management console that delivers operational visibility through integrated dashboards, enabling faster, data-driven decision-making for supervisors and managers.
Beyond picking, the solution introduced greater structure and visibility into staging and packing processes. Pickers digitally confirm staging locations, while live displays show how long each order has been staged and its current status. Packers select and confirm orders electronically, with productivity metrics, such as orders, lines and pieces packed, automatically captured and reported. This closed-loop process improves traceability, supports compliance requirements, and ensures consistent execution across shifts.
Silmid and Lucas Systems worked closely to tailor the solution to real operational conditions, resulting in a smooth go-live and rapid time to value. Within months, Silmid achieved efficiency gains exceeding 35%, throughput improvements of 60% and an accuracy rate of 99.9%. Backlogs that previously stretched three to four days were reduced to less than half a day, restoring the ability to reliably meet same-day and next-day delivery commitments.
The benefits extended well beyond operational metrics. Training time for new employees was reduced from several days to just two hours, highlighting the role of intuitive, user-centric technology in workforce enablement. Employee feedback has been highly positive, with picking roles becoming more engaging rather than a source of friction. This outcome aligns with Silmid’s broader philosophy of using technology to augment human capability, not replace it.
Building on these results, the organisation is now exploring additional automation and digitalisation initiatives as part of a longer-term process technology roadmap. The success of the initial deployment has laid a strong foundation for broader site digitalisation, reinforcing the value of automation that complements human expertise.
Silmid’s journey demonstrates how modern process technology, encompassing automation, control systems, digital workflows and AI-driven optimisation, can deliver tangible improvements in efficiency, accuracy and customer satisfaction. More broadly, it illustrates how manufacturers and distributors can future-proof their operations by aligning people, processes and technology around shared performance goals.
