Client Overview
A local automotive 4S dealership in Central China manages new vehicle delivery, after-sales service, and parts distribution for a Japanese passenger-car brand. The parts warehouse spans 1,200㎡ and stocks 6,000+ SKUs — from small filters and gaskets to bulky bumper assemblies, tires, and oil drums. With monthly service orders climbing, the original mixed
shelving could no longer support the weight or the pick volume safely.
The Challenge
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Overloaded shelves failing: Light-duty boltless units holding heavy brake discs, batteries, and suspension parts showed visible shelf sag and bent frames. Several units were propped up with timber blocks — a clear safety hazard.
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Bulky items on the floor: Bumpers, exhaust pipes, and tires sat in floor piles, blocking aisles and making it hard to locate the right part number during peak service hours.
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Small parts buried: Filters, spark plugs, and seals shared open shelves with heavy items, getting crushed or lost behind larger boxes. Pickers spent 8+ minutes per order hunting through unmarked zones.
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Wasted vertical space: 5.5 m clear height, but existing shelves topped out at 2.2 m. Upper wall space was entirely unused while floor aisles narrowed.
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WMS mismatch: The dealership's parts management system tracked bin locations, but the physical racking had no structured labeling — system said "in stock" while staff couldn't find the part.
Shibang's Tailored Solution
Shibang reviewed the parts catalog by weight and size, then delivered a two-tier heavy-duty system:
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Heavy-Duty Selective Racking (Bottom Tier): 800 kg/level rated frames for bulky, heavy items — tires, bumpers, batteries, oil drums. Reinforced box beams with safety-lock connectors prevent accidental disengagement during forklift loading.
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Medium-Duty Shelving (Upper Tier): 300 kg/level boltless shelving above the heavy rack zone for cartons of moderate-weight parts — brake pads, filters, electrical components. Adjustable shelf pitch (50 mm) adapts to varying carton heights.
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Small-Parts Bin Racking: Dedicated multi-tier bin walls for fast-moving consumables — spark plugs, clips, bulbs, gaskets. Color-coded bins with clear label holders synced to the dealership's parts management system.
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Tire Display Racks: Vertical tire storage stands along the side wall, holding up to 40 tires in a compact footprint with easy visual ID by size and model.
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Full-Height Layout: Combined system extends to 4.8 m, adding three effective storage levels and increasing parts capacity by 55% within the same footprint.
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Safety Package: Forklift impact guards on all
heavy-rack uprights, load capacity signage on every beam, and 3.0 m clear aisles for service-cart access.
Results & Impact
✅ 52% faster average parts-picking time per service order
✅ Zero shelf deformation or safety incidents at 4-month check
✅ 55% increase in effective parts storage capacity
✅ Small-parts loss eliminated — bin accuracy >99%
✅ Full aisle clearance restored — no floor-stacked obstacles
✅ WMS sync achieved — physical locations match system records
"Our parts team used to waste half the morning looking for items. Now everything has a place, the heavy stuff is off the floor, and the system actually matches what's on the shelf. Simple, solid, and safe."
— Parts Manager, Automotive 4S Dealership
Why Choose Shibang Racking?
18+ years delivering light-, medium-, and heavy-duty racking across automotive, textiles, apparel, printing, machinery, and 3PL. We engineer around your inventory profile, your space, and your workflow — no overkill, no compromise.
