Material Handling

Are You Managing Parts, or Just Moving Them Around?

Efficient material handling is about more than just moving parts


In a busy factory, it's easy to mistake movement for progress. Workers are on their feet, parts are constantly in motion, and there’s a daily hustle to keep production lines supplied. But here’s a question that every manufacturing leader should ask: Are we actually managing our parts, or are we just moving them around?

At first glance, the difference might seem subtle. But in practice, it’s the line between a reactive, inefficient process and a controlled, scalable operation. Let’s take a closer look at what it means to truly manage your materials, and how to identify when you're stuck in the trap of merely moving them.


Signs You’re Just Moving Parts Around

You may think you’ve got a solid material handling process in place. But if any of the following sound familiar, it might be time to reevaluate:

1. No Real-Time Visibility

You’re unsure where parts are at any given moment, especially once they’re staged or kitted. Inventory counts require double-checking. Receiving, staging, and production teams operate in silos without a shared view.

2. Frequent Searching

Operators or stockroom staff spend a significant portion of their time and energy hunting for parts. Looking through shelves, scanning bins, or chasing down paperwork to figure out what goes where.

3. Manual Checks and Rechecks

Picking a part for a job means grabbing a bin, checking labels, referencing pick sheets, checking again, and maybe even asking someone to confirm. Despite best efforts, errors still creep in.

4. Unclear Accountability

When something goes wrong, like a missing part or a mislabeled reel, no one’s quite sure when or where it happened. Processes rely on tribal knowledge instead of traceable systems.

5. Lots of Movement, Minimal Control

Parts move from stockroom to staging to production and back, but there’s little tracking in between. It’s a game of logistics rather than a coordinated, data-driven process.


What True Part Management Looks Like

Managing parts means more than making sure materials get to the production line. It means tracking, verifying, controlling, and optimizing every interaction with your inventory. It’s about creating a system that knows where every part is, what it’s for, and what needs to happen next.

Here’s what effective part management looks like in practice:

Real-Time Inventory Tracking

A central system, powered by smart storage with ERP/MES integration, provides live updates on what’s in stock, what’s been used, and where each package is located. You don’t guess, you know.

Automated Verification

Instead of relying on manual processes to double-check lot codes or manufacturer part numbers, the system does it for you. Smart storage solutions automatically choose the correct package for a job based on predefined rules like FIFO, MPN, or customer-specific requirements.

Unique Identification

Each package, reel, or tray is labeled with a unique ID that ties directly to its attributes, lot, date code, MSL, order number, and more. These IDs stay with the parts throughout their lifecycle, ensuring traceability and reducing errors.

Minimized Handling

Parts don’t need to be staged in bulk or passed through multiple hands. Lineside storage and on-demand picking ensure parts are available exactly when and where they’re needed, without redundant movement.

Integrated Systems

Smart receiving, storage, and production systems work together to close the loop. A part received at the dock is immediately labeled, logged, and ready for controlled storage or use, with every step recorded automatically.

Why This Matters

Poor part management leads to delays, mistakes, rework, and lost productivity. It makes it harder to scale, harder to train new employees, and harder to maintain quality. On the other hand, true part management:

  • Reduces manual labor

  • Improves traceability

  • Accelerates production

  • Supports better planning and forecasting

  • Builds resilience into your operations

In a competitive industry, moving parts isn’t enough. Manufacturers need visibility, control, and systems that make material handling smarter, not just faster.

Final Thoughts

If your team is constantly on the move but still struggling with part shortages, production delays, or inventory headaches, it’s time to rethink your material handling strategy. Because the goal isn’t to move parts more quickly, it’s to manage them intelligently.

The factories that win aren’t the busiest. They’re the ones with the best control. Are you managing your materials, or just moving them around?

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