HOW A MANUFACTURING FACILITY STREAMLINED INVENTORY MANAGEMENT AND IMPROVED MAINTENANCE EFFICIENCY

A large Fox Valley manufacturing facility struggled with an inefficient storeroom that made it difficult for maintenance teams to quickly locate materials and critical spare parts. Disorganized inventory, duplicate products from multiple manufacturers, and inconsistent SAP records created delays that increased downtime and operational costs.

The facility partnered with Werner to redesign and reorganize the storeroom. By combining structured inventory management practices, improved storage infrastructure, and hands-on implementation support, Werner helped transform the space into an organized, efficient operation that supports faster maintenance and improved inventory visibility.

DISORGANIZATION WAS DRIVING DOWNTIME

Over time, the facility’s warehouse had expanded without a clear strategy for stockroom management. As new materials were added and systems evolved, the storeroom became increasingly difficult to manage.

Several operational challenges began to impact productivity:

• Materials stored across multiple locations without standardized organization
• Duplicate products from different manufacturers
• Difficulty locating critical spare parts quickly
• Inconsistent and incomplete SAP records
• Limited inventory visibility and tracking
• Inefficient workflows within the storeroom

These challenges created operational risk. Maintenance teams often spent valuable time searching for parts, which extended equipment downtime and slowed production.

Additional common storeroom issues included:

• Uncontrolled inventory and poor tracking processes
• Excess inactive or obsolete spare parts
• Bloated inventory value and unnecessary MRO spending
• Lack of standardized processes and KPI tracking
• High turnover in storeroom and purchasing roles
• Aging assets requiring modernization

To move forward, Werner worked closely with the facility’s storeroom manager and leadership team to understand operational pain points and develop a customized improvement plan.

BUILDING A SMARTER STOREROOM SYSTEM

Werner implemented a structured storeroom optimization project designed to improve inventory management while minimizing disruption to daily operations.

The project began with a detailed review of the facility’s SAP system to identify existing products and confirm part numbers and locations. From there, Werner’s team systematically updated inventory records, printed new labels, and relocated items into newly organized storage areas.

A rotating team from Werner’s warehouse staff supported the physical work inside the facility. Each week focused on a specific product category, allowing the storeroom to continue operating without interrupting production.

Werner also managed the physical transformation of the storeroom, including the installation of new storage infrastructure to support better organization and accessibility.

Implementation Steps:

• Step 1: Consultation Werner collaborated with facility stakeholders to evaluate the existing storeroom and develop a structured reorganization plan.
• Step 2: Storage Installation New cabinetry and pallet shelving were installed to support improved storage and accessibility.
• Step 3: Storeroom Reorganization Products were labeled, cataloged, and relocated according to a standardized organizational system.

Throughout the project, a dedicated Werner team member remained onsite to coordinate work, answer questions, and ensure progress stayed aligned with operational needs.

A STOREROOM BUILT FOR RELIABILITY

Over the course of the year-long project, the storeroom was reorganized to support faster workflows and more reliable inventory management.

Key outcomes included:

• 8,970 spare parts relocated and organized
• Improved inventory visibility and accuracy
• Reduced time spent searching for parts
• Identification of duplicate and obsolete inventory
• Lower MRO spending through better inventory control
• Increased reliability through improved spare part availability
• More efficient storeroom workflows

With a standardized structure in place, maintenance and storeroom teams can quickly locate the materials they need without searching across multiple storage areas. Updated SAP records also provide clearer visibility into inventory levels and part locations.

As materials were cataloged and relocated, the team uncovered duplicate parts and inactive inventory that had accumulated over time. Identifying these items helped the facility reduce excess stock and better manage MRO spending.

Clear labeling, defined storage locations, and improved inventory records also created a more consistent workflow for the team responsible for managing the storeroom. By the end of the project, the space had evolved from a difficult-to-manage storage area into a more organized system that better supports daily maintenance operations.