The Need for an Efficient Change Parts Storage Solution
As manufacturing operations scale, so does the complexity of managing change parts. Our customer, a large-scale manufacturer, faced challenges in organizing and storing change parts due to the increasing variety of bottle sizes and formats. They needed a flexible storage solution that could adapt to their evolving needs while ensuring safety, accessibility, and cost efficiency.
Their existing system relied on ad-hoc storage solutions, leading to inconsistent organization. Some parts were placed on open shelving, while others were stacked on top of each other without clear labeling. This made retrieval time-consuming and increased the risk of losing or damaging valuable components. Employees often had to search multiple locations to find the right parts, which slowed down production. Our customer needed a reliable, long-term storage strategy to streamline their operations.
Challenge: Overcoming Change Part Storage Inefficiencies & Downtime
With a growing number of change parts in use, the customer faced several operational roadblocks:
● Managing Multiple Change Parts – Star wheels, chucks, case packer grids, and label pallets were scattered across different areas, making them difficult to track and store efficiently.
● Inefficient Storage – Poor organization led to misplaced or damaged parts, causing costly delays.
● Production Downtime – Lost, broken, and misplaced parts resulted in unexpected operational slowdowns, production delays, and expensive replacements.
● Limited Mobility – Employees had no easy way to transport parts between machines, adding further inefficiencies.
Employees were spending valuable time searching for change parts. This inconsistency in storage practices resulted in frequent errors and misplacements, causing further downtime and unnecessary costs. As production demands increased, the inefficiencies became more apparent, reinforcing the urgent need for a structured, scalable storage system.
Solution: A Custom Wall & Cart System for Maximum Efficiency
We provided our customer with a full plant wall and cart system, offering a custom storage solution designed to:
● Enhance Organization – Custom boxes and holders securely attach change parts to walls and carts, ensuring every part has a designated place.
● Improve Accessibility – Parts are safely stored and easily transported, reducing downtime and enhancing operational efficiency.
● Prevent Misplacement and Damage – Properly secured storage minimizes part loss and breakage, reducing unplanned downtime and associated costs.
● Ensure Scalability – The system can grow with the facility’s changing storage needs, adapting to new bottle formats and machinery.
By implementing this solution, our customer transformed how they managed change parts. The wall system featured modular components that could be adjusted as needed, while the mobile carts made it easy to transport parts across production lines. Each part was clearly labeled, reducing confusion and making inventory checks more efficient. By strategically placing storage walls and mobile carts in key locations across the facility, we ensured that change parts were always within arm’s reach.
Results: A More Efficient, Cost-Effective Operation
After implementing the custom storage system, our customer saw immediate improvements:
● Increased Efficiency – Faster retrieval and transportation of change parts.
● Reduced Costs – Minimized losses from misplaced or damaged parts.
● Improved Uptime – Less downtime due to misplaced or broken parts, keeping production on schedule.
● Enhanced Safety – Secure storage reduces workplace hazards and prolongs the lifespan of components.
The impact was felt across the company. Employees are now able to spend far less time searching for parts, allowing them to focus on their primary tasks. Over time, these small improvements compounded, creating a more streamlined, productive, and safe work environment.
Conclusion: A Scalable Change Parts Storage Solution for Long-Term Success
By adopting our custom wall and cart system, our customer turned a disorganized storage process into a seamless, efficient, and cost-effective operation. This solution demonstrates the importance of adaptable storage in dynamic manufacturing environments.
Moving forward, the company now has a scalable storage infrastructure that can grow alongside its manufacturing needs. The success of this implementation has set a new standard for how change parts should be organized and managed, serving as a benchmark for future process improvements. With improved efficiency, reduced costs, and enhanced safety, this solution has positioned the company for sustained operational excellence.
As manufacturing continues to evolve, companies that prioritize adaptable, high-efficiency storage solutions will maintain a competitive edge.
Optimize Your Change Parts Storage with Our Custom Solutions
Looking to improve your change parts storage? Our custom wall boards and cart systemsoffer the perfect solution to improve organization, increase efficiency, and reduce downtime. Designed to grow with your manufacturing needs, our flexible storage solutions ensure safety, accessibility, and cost savings.
Don't let inefficiencies slow down your operations. Get in touch today to discover how our carts and wall boards can help streamline your workflow and position your company for long-term success.
Loading... Please wait...
