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Automotive Spare Parts Warehouse Automation Case Study: FAW Toyota Project
Automotive spare parts warehouses are usually more complex than standard finished goods warehouses. They need to manage thousands of SKUs, different packaging formats, large and small parts, irregular components, return parts, dealer distribution, and frequent picking tasks.
In the FAW Toyota spare parts warehouse project, DELIECN worked with Bangsheng Logistics to support the automation upgrade of an automotive parts warehouse in Changshu. The warehouse serves spare parts storage and distribution operations, covering parts from factories, suppliers, parts centers, and dealer return flows.
The project involved multiple material types, including small parts, large parts, bumpers, oil products, and non-standard components. Instead of using one storage method for all materials, DELIECN designed a multi-zone automated warehouse system.
Project Challenges
The warehouse needed to manage nearly 45,000 SKUs. Different parts had different dimensions, weights, packaging forms, turnover frequencies, and picking requirements.
The main challenge was not only storage capacity. The customer needed a system that could support:
- multi-SKU inventory management
- mixed-size spare parts storage
- large and small material separation
- inbound, storage, picking, replenishment, outbound, return, and inventory processes
- FIFO and traceability requirements
- connection between multiple storage zones and operation areas
- stable long-term operation
For this type of automotive spare parts warehouse, a single ASRS type cannot cover all needs. Different materials need different storage and handling methods.
DELIECN Solution
DELIECN designed a combined Warehouse Automation solution, including:
- Pallet Four-Way Shuttle Asrs for large spare parts
- Mini-FlyBox ASRS for small parts and high-SKU items
- VNA racking for relatively standardized large parts
- dedicated narrow-aisle storage for bumpers
- Mezzanine Racking for irregular and low-frequency parts
- TOTE AMRs and AGVs for multi-zone material transfer
- WMS, WCS, API, and ECS for system coordination
- 3D visualization and central monitoring
This system matched different automotive spare parts with suitable storage methods, helping the customer move from separated manual operations to a more connected automated warehouse flow.
How the System Works
Large automotive spare parts are stored in the pallet four-way shuttle ASRS.The system uses pallet four-way shuttle robots, Shuttle Racking, level-changing lifters, and conveyors to support dense storage and automatic retrieval.
Small parts and high-SKU items are stored in the Mini-FlyBox ASRS. Standard totes are used to support Automated Storage, outbound flow, and goods-to-person picking.
Irregular parts, low-frequency parts, bumpers, and larger components are handled through VNA racking and mezzanine storage areas. AMRs and AGVs connect different zones, reducing manual cross-zone handling.
Project Value
After implementation, the project helped shorten the spare parts logistics chain and improve warehouse response. According to the project summary, the customer’s supply chain link was shortened by about 80%, and the supply cycle was reduced from 8 days to 2 days.
For automotive spare parts warehouses, this value is critical. Faster parts response means better support for dealer distribution, maintenance parts supply, returns handling, and inventory traceability.
Why This Case Matters
This project shows that automotive spare parts automation is not about choosing one product. It requires a complete system that can match different part types with different storage modes.
For customers managing large SKU volumes, mixed-size parts, and multiple warehouse processes, the key is to build a flexible multi-zone warehouse that can connect storage, picking, transfer, outbound, and data traceability.
Planning an automotive spare parts warehouse automation project?
Talk to DELIECN about pallet Shuttle Asrs, tote ASRS, AMR/AGV transfer, multi-zone storage, and WMS/WCS integration for automotive spare parts warehouses.