The Automotive Parts Distribution Industry is one of the most demanding sectors in distribution. With tight carrier deadlines, complex product handling requirements, and constant labor pressures, distributors face unique challenges that few other industries encounter. In this edition of Conveyco’s SME Blog Series, we sat down with Bryan Gionet, who brings nearly two decades of experience across project management, site operations, equipment rebuilds, and hands-on conveyor expertise. Bryan has witnessed firsthand how automation strategies are reshaping automotive parts distribution and why flexibility and accuracy are the new cornerstones of success.
The Daily “Crunch Time” Every Auto Parts Distributors Knows
One of the toughest challenges in auto parts fulfillment is the 2:00 PM order surge. The majority of customer orders arrive in the afternoon, but they still need to be processed, packed, and shipped the same day before the last carrier truck departs.
“That means if you don’t have automation in place to maximize order turnaround speed, you’re stuck paying for late pickups or costly overnight services” Bryan explains.
Many companies negotiate extended pickup windows with carriers like FedEx, UPS, and USPS, sometimes pushing collection times as late as 7:00 PM. However, these extended hours come at a premium. A single order error can escalate into costly overnight shipping charges, making order accuracy just as important as speed.
Two Worlds Under One Roof: Small vs. Oversized Auto Parts
Unlike many industries, auto parts distribution deals with two very different types of products:
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Small, high volume parts like filters, spark plugs, and electronics, which fit perfectly into goods-to-person automation solutions like Autostore and Exotec.
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Large, bulky items like bumpers, rotors, and tires, which often resist automation due to weight and size constraints.
This duality creates a unique challenge. “Traditional AMRs can handle small items efficiently, but heavy products like rotors tend to cause tipping issues. That’s where shuttle-based and hive style storage systems are now proving their worth,” says Bryan.
By integrating high-density automated storage for small parts with pallet shuttle systems for larger items, distributors can reduce their warehouse footprint by up to 50%, all while ensuring that SKUs of any size are handled effectively.
Accuracy Is the Profit Protector
In auto parts fulfillment, accuracy is non-negotiable. As previously highlighted, one wrong pick not only frustrates customers but also forces distributors into overnight shipping expenses.
That’s why Bryan emphasized multi-stage verification:
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Batch picking with put-to-light consolidation ensures correct order assembly
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Checkweighers and weigh-in-motion scales confirm every carton matches WMS data
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Print-and-apply labeling and automated sortation finalize the process
All of these elements work together to create a closed-loop system of accuracy, adding extra layers of assurance that reduce costly mistakes and increase throughput speed.
“Accuracy is really the hidden profit driver,” Bryan said. “The right automation makes sure errors are caught before the package leaves the building.”
Labor Pressures are Driving Automation Faster
Labor market volatility is another major driver of automation in this space. Whether it’s competing with wages in California Inland Empire or struggling to staff remote warehouses in the Midwest, auto parts distributors are constantly battling turnover and wage inflation.
Automation alleviates these pressures by:
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Reducing reliance on scarce labor during crunch periods
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Simplifying training through user-friendly, light-directed picking systems
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Designing “error-proof” processes that accommodate high turnover
“Systems today are designed to be intuitive,” Bryan explained. “Operators can be trained in hours, not weeks, which is critical in today’s labor market.
The Role of WES: Orchestrating a Complex Environment
Most auto parts distributors run multiple automation technologies—AutoStore for small parts, conveyors for case flow, AMRs for transport. But unless these systems are orchestrated, they can operate as “islands of automation,” leading to bottlenecks and inefficiencies.
This is where Conveyco's New Dawn Warehouse Execution System (WES) becomes essential, acting as the conductor of the orchestra, ensuring each component of the operation works in harmony. With its web-based and modular architecture, the system offers real-time dashboards accessible from anywhere, providing seamless orchestration of AutoStore, AMRs, conveyors, and conventional pick modules. Additionally, it boasts universal compatibility with major WMS platforms like Manhattan, SAP, or even homegrown systems.
“The real power comes from the software layer,” Bryan said. “You can have the best automation in the world, but if it’s not synchronized, you’ll still have bottlenecks.”
Proven Success: Lane Automotive
Lane Automotive, a leading distributor of performance automotive parts, has steadily scaled its automation over the past decade. But when they implemented an automated storage and retrieval system (ASRS), they discovered a major gap: while the system tracked where the totes were, it couldn’t track what was inside them. This forced operators to manually recount and re-enter SKUs, slowing operations, increasing errors, and eroding trust in inventory data.
Conveyco solved this by integrating our New Dawn Warehouse Execution System (WES). Unlike the ASRS’s limited logic, New Dawn WES delivers slot-by-slot visibility control without replacing existing automation. Using emulation tools, the solution was stress-tested before go live, ensuring smooth deployment with zero disruption.
Today, Lane Automotive enjoys a fully automated storage and picking solution, with synchronized inventory across pick, pack, and ship. “By layering in New Dawn WES, they not only fixed critical gaps but also unlocked the full potential of their ASRS investment” Bryan explains. This demonstrates how automation can grow in phases and adapt as operations evolve.
Looking Ahead
Auto parts distributors are at a critical crossroads. Same day expectations, labor challenges, and competitive pressures aren’t going away, they’re intensifying. Automation, when properly integrated and orchestrated, provides the path forward.
Bryan sums it up best:
“Automation isn’t just about speed. It’s about accuracy, flexibility, and scalability. The distributors who get this right aren’t just surviving, they’re setting the standard for the future of auto parts distribution.”
What’s the next step? Want to see how automation can help your auto parts operation handle crunch time with confidence? Contact Conveyco’s team of experts to start the conversation.
Meet Bryan Gionet
Bryan Gionet is a long-term team member at Conveyco, bringing 19 years of experience across multiple areas of business. His career path has taken him through project management, site management, parts development leadership, equipment rebuilds, and on-site installations. This gives him a uniquely well-rounded understanding of conveyor systems and automation solutions.
Bryan applied his background in Graphic Design to build Conveyco's parts website, helping grow the business tremendously. He later specialized in equipment rebuilds, including Walmart sorter projects, where he managed direct quoting responsibilities and hands-on execution. Along the way, Bryan developed comprehensive conveyor expertise, with direct involvement in design, sales, installation, and maintenance.
Outside of his day-to-day work, Bryan enjoys finding creative outlets for his artistic background. With a Art degree, he brings an eye for creativity and problem-solving to every project. This unique perspective continues to influence his approach to automation and supply chain solutions.
