Modernize Auto Parts Warehousing – OPEX^® Perfect Pick^®

Optimizing Accuracy, Speed, and Space Utilization in a Complex Supply Chain

Transforming Auto Parts Fulfillment Process

The auto parts industry handles a diverse inventory of stock-keeping units (SKUs), ranging from small, lightweight components to large, heavy items. With varying levels of demand and complexity, warehouses are tasked with meeting the needs of both B2B and B2C customers while adhering to tight delivery timelines. Traditional order fulfillment practices often rely on manual workflows for receiving, storing, picking, and shipping. These processes, while functional, are time-consuming and prone to inefficiencies, especially when scaling operations to meet increased demand or managing rapid-turnaround tasks such as emergency orders.

“Perfect Pick allows us to maximize storage capacity in a fairly small footprint, while increasing efficiencies in meeting high-volume output.”

Vic Ricci

Senior Vice President Operations, Knipper

Challenges Faced By Manual Order Fulfillment

Manual operations in auto parts warehouses present significant hurdles. The reliance on labor-intensive processes increases operational costs and makes businesses vulnerable to labor shortages, particularly during seasonal spikes. Traditional storage systems often fail to make efficient use of warehouse space, leading to congestion and reduced storage capacity. Additionally, manual picking methods contribute to higher error rates, with incorrect shipments resulting in increased returns, dissatisfied customers, and financial loss. Picking heavier items and transporting them through the warehouse can create additional challenges including the risk of injury to employees. As customer expectations for faster and accurate deliveries grow, the limitations of manual systems become more apparent, hindering businesses from staying competitive.

Enhanced Accuracy
Guided operator picking ensure secure, accurate orders.

Scalability and Flexibility
Add expansion modules and iBots to accommodate more inventory.

Improved Efficiency
Automated inventory control prioritizes key products.

The Transformative Impact of OPEX Perfect Pick

The OPEX^® Perfect Pick^®system modernizes order fulfillment for the auto parts industry, seamlessly integrating automation into warehouse operations. Perfect Pick’s high-density storage design utilizes vertical space to store a vast range of SKUs on trays or in various tote sizes with dividers. This arrangement not only maximizes storage capacity, but also ensures secure and precise organization, catering to the diverse sizes and weights of inventory up to 80lbs (36.2 kg).

At the heart of Perfect Pick’s efficiency is its iBOT^® technology—autonomous, wireless robotic vehicles that navigate the system’s aisles to retrieve and deliver inventory. These iBOTs are self-charging and operate on a closed-circuit system, minimizing downtime and ensuring continuous operation. iBOTs locate the required totes or trays and transport them directly to ergonomically designed pick stations, eliminating the need for workers to navigate the warehouse. This goods-to-person approach drastically reduces employee travel time and physical strain, improving both productivity and workplace safety.

The system integrates seamlessly with existing Warehouse Management Systems (WMS), enabling real-time inventory and order tracking while ensuring efficient coordination between order requirements, inventory management, and picking operations. It optimizes tote slotting by prioritizing high-demand items, often referred to as A-movers, ensuring these frequently needed parts are easily accessible for rapid fulfillment. This streamlined integration allows the system to enhance order sequencing and overall operational efficiency, meeting the fast-paced demands of the auto parts industry. Hot picks or emergency orders can be prioritized and presented at pick stations in minutes without disrupting ongoing operations. This capability is vital for fulfilling time-sensitive requests for repair shops or service centers that depend on receiving parts promptly.

The system is also adaptable for mixed workflows. Perfect Pick consolidates smaller parts into automated picking workflows, while larger or bulk items can be manually picked and integrated into the final order. The system also allows for simultaneous item picking and put-away. This ensures flexibility and efficiency, even for warehouses managing diverse inventory types. By combining automation for smaller, high-velocity items with manual handling for oversized components, Perfect Pick provides a comprehensive solution tailored to the auto parts industry’s unique requirements.

>2.6M

Items picked by
perfect pick

8:1

Space Savings 

Years or less to achieve ROI

Benefits of Perfect in Auto Parts Workflow

Integrating Perfect Pick into auto parts order fulfillment workflows offers a wealth of benefits that address the industry’s key pain points. Automation streamlines operations, leading to faster processing times and reduced dependency on labor, which in turn lowers costs. The system’s precision dramatically reduces picking errors, enhancing order accuracy and customer satisfaction. By optimizing vertical storage, warehouses can store more inventory and maintain better organization, even in constrained spaces. Perfect Pick’s scalability provides flexibility for businesses to grow or contract operations without significant additional investments. Overall, this automated system ensures lower costs per order, improved throughput, and the ability to deliver exceptional customer service.

Did you know?

Perfect Pick iBOTs can carry payloads up to 80lbs (36.2 kg).

Perfect Pick Totes are in various sizes and can be subdivided to hold multiple SKUs. Flat trays are also available for custom containers.

Present stations can be placed at front and back of the Perfect Pick aisle. They can also be placed on a mezzanine for faster access below for uninterrupted maintenance.

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