Most factories have at least one area where parts are just stacked on pallets and left. It works, sort of. But over time it costs more than people realise, and not just in damaged components.
The real cost of poor parts handling
When a component gets damaged on the shop floor, the obvious cost is the part itself. But there’s the labour to sort it, the delay it causes, and if it gets missed before it goes into a vehicle, you’ve got a much bigger problem downstream.
A lot of that damage happens during storage and transit between stations, not during the actual production process. Parts get knocked, scratched, or crushed because they weren’t stored in a way that suits them. And often it’s simply because the business never had the right equipment in place.
What stillages actually do
Stillages are load-bearing frames designed to hold parts in a fixed, repeatable position. That’s really it. But the difference between a standard stillage and one built for your specific component can be significant.
Bespoke stillages are designed around the part rather than the other way round. That matters when you’re handling irregular shapes, large panels, or anything with a finish that can’t be touched along certain surfaces. Off-the-shelf options might get the job done, but they often mean extra packaging, more movement inside the frame, and a higher chance of contact damage.
A well-designed stillage also means your team handles parts the same way every time. That consistency reduces errors and speeds things up at each station.
Getting components from A to B
Storage is only part of the equation. Parts don’t stay still, they move between suppliers, sub-assemblies, production lines, and final build. Each time a component changes hands there’s an opportunity for something to go wrong.
The supplier side of things
Most manufacturers don’t build everything in-house. Parts come in from multiple suppliers, sometimes from different countries, and they need to arrive in a usable condition. That means the packaging and handling equipment needs to work across the whole chain, not just inside your own site.
It’s worth thinking about this early. If your suppliers are packing parts into generic crates and you’re unloading them into bespoke carriers at the dock, you’re adding a step that could be removed. Some businesses work with their suppliers to standardise the carriers from the point of manufacture, which reduces handling at both ends.
How automotive logistics fits into this
Automotive logistics covers the movement and management of components through the entire supply chain, from raw materials to the finished vehicle. It’s a broad term but the detail matters.
In a sequenced production environment, parts need to arrive at the line in the right order, at the right time, in the right condition. If one of those three things is off, the line either slows down or stops. And downtime in automotive manufacturing is expensive, not just inconvenient.
Sequencing and the knock-on effects
Sequencing means that components arrive just before they’re needed, often in the exact order they’ll be fitted. There’s no buffer stock sitting on the floor waiting. That works really well when everything goes to plan, and it creates problems fast when it doesn’t.
The physical handling equipment has to support that system. If a stillage is the wrong height for your line-side racks, or if it can’t be moved by your existing handling equipment, it adds friction to a process that’s designed to run tight. Small mismatches in equipment add up over thousands of cycles.
Designing equipment around the process
The tendency is to buy equipment and then fit the process around it. That works fine for general warehousing but it’s not ideal in an automotive context where the margins are tighter.
The better approach is to map out the journey a component takes from supplier to point of fit, and then work out what equipment is needed at each stage. That might mean a returnable transit carrier that’s compatible with the supplier’s racking, a stillage that fits into a specific section of the line, and a trolley that lets operators move it without a forklift.
None of those things are complicated on their own. But they need to be specified together or you end up with kit that doesn’t quite connect at each handover point.
Returnable versus single-use packaging
Single-use packaging is common when components come in from suppliers who aren’t set up for returnables. It’s convenient short-term but the costs add up. You’re paying for the packaging each time, dealing with waste disposal, and often building in more handling because the packaging isn’t designed for your process.
Returnable systems have a higher upfront cost but tend to work out cheaper over time, and they’re easier to manage on the line. The carrier comes back, gets checked, and goes out again. There’s also less variation in how parts arrive, which makes the process more predictable.
The decision usually comes down to volume and the nature of the supplier relationship. Low volume or one-off suppliers often don’t justify the investment in returnables. High-volume, long-term supply agreements usually do.
What to look at when reviewing your current setup
If you’re not sure whether your current equipment is holding you back, a few things are worth checking.
How often are parts damaged between delivery and point of use? If it’s happening regularly, the carrier or storage method is probably a factor. How much time do operators spend adjusting parts or re-packing before they can use them? That’s a sign the equipment isn’t quite right for the component. And are there any points in the process where parts have to be manually transferred from one carrier to another? Each of those transfers is a risk.
None of these issues are unusual. Most sites have at least one area where the equipment is a compromise. The question is whether the compromise is costing enough to justify a change.
Keeping it simple
There’s a tendency to overcomplicate this. At its core, parts handling is about moving the right component to the right place without damaging it or wasting time. The equipment is just a means to that end.
But getting the equipment right does make a real difference, particularly in high-volume environments where small inefficiencies repeat themselves thousands of times a day. It’s worth looking at it properly rather than just accepting the current setup as good enough.
