The shift from traditional shelving to intelligent automated storage systems is revolutionising maintenance, repair, and operations (MRO), delivering significant efficiency gains, space savings, and operational resilience for manufacturing facilities.
Maintenance, repair, and operations (MRO) stand at the core of manufacturing facility efficiency, yet many facilities struggle with outdated spare parts storage systems that hamper productivity and elevate downtime risks. ...
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Traditional approaches involving rows of shelving, bins, and manual inventory tracking often lead to hidden inefficiencies such as excess search time, poor part visibility, low pick accuracy, and suboptimal space utilisation. These issues culminate in higher operational costs and extended production halts when critical equipment fails and parts are not immediately accessible.
Modern automated spare parts storage systems offer a transformative solution by replacing manual handling with intelligent, vertical storage modules integrated with advanced inventory management software. Such systems significantly reduce downtime by delivering precise parts to technicians within seconds, eliminating time lost to searching or tolling manual logs. According to Kardex, leaders in automated storage technology, these systems also boost technician productivity by allowing skilled workers to focus on maintenance tasks rather than part retrieval or record keeping.
Automated vertical lift modules (VLMs) and vertical carousel modules (VCMs) are the primary technologies utilised. VLMs excel in storing heavy, bulky items in enclosed trays that can integrate with handling systems such as cranes or conveyors, reclaiming up to 85% of floor space and enhancing safety and ergonomics by delivering parts at comfortable heights. VCMs cater to smaller to medium-sized components with rotatable carriers that facilitate quick and accurate picking in compact footprints suitable for space-constrained environments.
The advantages extend beyond mere storage density and speed. Integrated inventory management software, such as Kardex’s Power Pick System, provides real-time visibility into stock levels, traceability of parts by technician or machine, automated reorder alerts, and detailed audit reporting. This level of control eradicates issues like misplaced or expired parts, reduces duplicate orders, and enables precise cost allocation to different departments or projects.
Operational successes underscore these benefits. For instance, Jazz Aviation’s adoption of Kardex automated storage led to a 77% increase in MRO productivity, 99% pick accuracy, and a 71% reduction in storage footprint. Similarly, Plasser American achieved a 70% space reduction, near-perfect pick accuracy, and a 20% reduction in labour needs by transitioning to automated modules.
Complementary innovations further elevate spare parts management. Smart warehousing leverages RFID tags, IoT sensors, and AI-driven analytics to forecast spare parts demand, optimise stocking levels, and trigger maintenance workflows preemptively, ensuring parts availability aligns tightly with operational needs. Automated robotic retrieval and intelligent layout design offer even faster access while maximising floor space. Additionally, 3D printing is emerging as a disruptive technology, allowing manufacturers to produce on-demand parts digitally, cutting inventory costs and supply chain vulnerabilities—particularly beneficial for obsolete or custom components.
Moreover, high-density storage systems supplied by companies such as Shelf Plus deliver significant reductions in inventory floor space (up to 80%) and supply usage, while boosting inventory accuracy by as much as 50%, contributing to lower overall maintenance costs and reduced downtime. Facilities using automated multi-column vertical warehouses, like ICAM’s SILO system, benefit from secure, controlled storage with seamless software integration to monitor stock in real time, thereby mitigating out-of-stock events that often trigger costly production stoppages.
Collectively, these advancements mean automated spare parts storage is no longer a luxury, but a strategic necessity for manufacturing operations seeking to remain competitive. By automating retrieval, improving accuracy, and enabling data-driven insights, companies can unlock meaningful productivity gains, reduce waste and damage to parts, increase worker safety, and free valuable space for revenue-generating processes. As manufacturing demands grow and complexity intensifies, scaled, modular systems like VLMs and VCMs ensure spare parts management evolves without limiting facility growth.
The shift toward automation and digital integration in MRO parts storage represents an investment in operational resilience—transforming storerooms from passive inventory repositories into active enablers of uptime and efficiency. For facilities grappling with the constraints of traditional shelving, embracing automated storage with intelligent inventory controls offers immediate and measurable returns, safeguarding against unplanned downtime and supporting long-term growth.
Source: Noah Wire Services
