Stories U.S car parts manufacturer

U.S. car parts manufacturer — Twice the orders, same warehouse.

U.S car parts manufacturer

United States

Manufacturing/Industrial, Ecommerce

Stories U.S car parts manufacturer

Warehouse worker scanning car parts on shelving with a ring scanner and tablet running the Pio App

For this U.S. car parts manufacturer, making the parts is only half the job. Customer orders, incoming inventory and parts from production all had to move through the same warehouse, and the space was running out. The team needed a smarter way to store, pick and put away without adding more footprint. That's where Pio came in.

Built to keep things moving.

Almost 2x orders per day

95% fewer picks per work order

Faster inbound and putaway

More capacity, same warehouse

BClose-up of a Pio port in a car parts manufacturer's warehouse

Operator using the Pio App on a tablet to pick car parts at a Pio port

Car parts being packed for shipping at a warehouse workstation

Pio port where a U.S. car parts manufacturer picks complete work orders from pre-kitted bins

Pio cube storage using vertical space to fit more car parts in the same warehouse

The Challenge

Manufacturing in-house is what sets this company apart from many ecommerce businesses. Alongside customer orders that need to be picked and shipped, and incoming inventory that needs to be put away, the warehouse also has to handle parts coming from production, all within the same space.

Picking was another challenge. The team picked not only customer orders, but work orders too. A work order is an order that requires many different parts for a specific job. Each part had to be found and picked individually, and some work orders included more than 100 order lines, making the process time-consuming.

Incoming inventory added to the workload too. Larger deliveries could sometimes take up to a week to put away. As inventory grew, the team also needed more storage capacity without adding more warehouse space.

Keeping everything moving was getting harder.

Two operators picking car parts at Pio ports in front of the cube storage grid, with bin carts beside them

The Solution

Pio gave the team an automated way to store and retrieve parts faster, making use of vertical space that had previously gone unused.

Picking got simpler too. With parts already organized into kits in Pio, operators can pick a complete work order in a few steps instead of working through every order line individually.

“Instead of picking 108 order lines, we're picking 5 because we have everything already kitted up.”

Tommy
Warehouse Manager at a U.S. car parts manufacturer

The team can also pick and put away inventory at the same time. Incoming parts can be stored throughout the day without getting in the way of customer orders.

And not everything has to fit inside the grid. Larger items stay on the shelf, while the Pio App still keeps track of them using barcode scanners and product images on screen.

Results and Impact

After switching to Pio, this U.S. car parts manufacturer saw improvements across the operation:

Almost twice as many orders per day
The team moves close to double the daily order volume it handled before Pio, with the same people and the same space.
95% fewer picks per work order
With parts stored as kits in Pio, a work order that used to mean 108 separate picks now takes 5 picks.
Faster inbound and putaway
Large deliveries that used to take up to a week to put away are now stored within days, while customer orders continue to be picked.
More capacity in the same warehouse
The team uses vertical space to store more inventory within its existing warehouse footprint.
Accountability and inventory control
Every item's location and putaway history is visible, so misplaced stock is easy to find and fix.

“Since Pio, we are able to move almost twice as many orders in a day. We're definitely able to produce at a higher level.”

Tommy
Warehouse Manager at a U.S. car parts manufacturer

Unexpected Benefits

Beyond higher order volumes and faster warehouse operations, Pio also made day-to-day work easier.

Easier onboarding
Product images on screen make it easier for new employees to find the right products and get up to speed.
Home on time
The team can store incoming inventory while continuing to pick orders, helping them finish the day’s work on time.

“Being able to store inventory while we're picking lets me go home on time.”

Tommy
Warehouse Manager at a U.S. car parts manufacturer

Looking Ahead

Pio has already grown once with this manufacturer, from a P100 to a P200, and it's ready to go again. As the business grows, industrial automation is helping the warehouse keep up, with more capacity and more orders moving through the same space.

For this manufacturer, Pio isn't just faster storage. It's a competitive advantage, and one they'd rather not share, which is why the company asked to remain anonymous.

"Pio is a huge competitive advantage. We're definitely able to produce at a higher level."

Tommy

Warehouse Manager at a U.S. car parts manufacturer

The Results

Pio helps this U.S. car parts manufacturer process more orders, store more inventory and keep products moving faster, all within the warehouse it already has.

Almost twice as many orders per day. Close to double the daily order volume, with the same team and the same space.

95% fewer picks per work order. With parts stored as kits in Pio, a work order that used to mean 108 separate picks now takes 5.

More capacity in the same warehouse. Vertical storage up to 22 feet high, where the customer has already expanded from a P100 to a P200 to add more products.