Parts Authority

The Client

Parts Authority distributes automotive and truck parts to the aftermarket auto parts industry in the US.

The Challenge

High labor costs were associated with picking 100K+ SKUs over a large warehouse encompassing multiple floors. Finding enough labor to do the work proved difficult, and the cost of goods out the door was higher than needed. Order picking was time-consuming and required consolidation due to different pickers selecting parts in various warehouse areas.

The Solution

KPI implemented a high-density, efficient AutoStore storage solution for parts that fit into the AutoStore bins and Geek+ P800 AMR racks for more oversized bulky products. AutoStore retrieves parts for multiple orders at a time and delivers them to the operator at a port, where items are picked. When the order is complete, it is pushed onto a takeaway conveyor.

Geek+ operates similarly, working in a non-conveyable picking area for larger parts. All orders are delivered via conveyor to a pack-out process where order confirmation and packing occur. This area also utilizes automated taping and automatic print & apply for ship label application, before the carrier automatically sorts outbound cartons.

KPI worked with the client for several months on various solution options before settling on the final system. The collaboration of all parties resulted in a hybrid system design that supports streamlined and accurate omnichannel fulfillment. This highly-efficient automated solution resulted in a 40% staff reduction and ~60 fewer FTEs in the building.

The Value