This regional automotive components distribution center primarily serves nearby assembly plants, repair networks, and distributors. Stored inventory includes palletized engine parts, braking systems, suspension systems, packaged body components, and aftermarket consumables.

Before the upgrade, the warehouse relied on traditional floor stacking and low-level storage, severely wasting high-level vertical space. With business expansion and increasing SKUs, the legacy model resulted in excessive forklift travel paths for put-away and replenishment, making it difficult to clearly zone fast-moving goods, safety stock, and heavy components.

• Complex pallet sizes, product weights, and packaging heights made unified management difficult.
• Frequent capacity overflow during seasonal inventory peaks required renting external temporary warehouses.
• Heavy automotive chassis parts competed with high-frequency fast-moving SKUs for prime ground-level storage space.
• Unclear warehouse routing led to redundant forklift travel and increased search times.

Adhering to the latest warehousing and logistics industry standards, we introduced a selective heavy-duty pallet racking system with adjustable beams. The design comprehensively factored in maximum pallet loads, forklift turning radii, clear building height, and the turnover rates (velocity) of various SKUs. This ensured 100% direct access to every position, perfectly accommodating the complex inbound and outbound operations of automotive components.

For slotting allocation, the lower levels were dedicated to high-density and heavy components; middle and upper levels for reserve stock; and bays closest to main aisles were reserved for high-frequency SKUs. Receiving, reserve, picking, and dispatch zones were physically and dynamically separated to guarantee smooth material flow.

• Standard three-level storage design with a safe load capacity of 1,500 kg per pallet.
• Achieved 100% direct forklift access, eliminating product crushing and operational interference.
• Scientifically partitioned receiving, fast-moving, reserve, and dispatch zones.
• High-frequency operational aisles fully equipped with upright protectors and row-end barriers.

Upon project delivery and operation, 1,248 new pallet positions were successfully added without leasing any additional facility footprint. By slotting high-frequency SKUs forward and isolating safety stock, forklift travel distances were drastically shortened, leading to a significant increase in inventory turnover efficiency.

• Storage Capacity Jump: Pallet positions increased from 1,920 to 3,168, realizing a net growth of 65%.
• Space Utilization: Fully activated vertical building space, boosting utilization from 36% to 59%.
• Operational Routing Optimization: Redesigned warehouse layout reduced actual forklift single-trip travel distance by 18%.
• Eliminated Extra Costs: The new positions fully absorbed business volume increments, completely eliminating the need to lease external overflow warehouses.