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Keystone Automotive Opens Massive New Distribution Warehouse

Posted in News on October 4, 2018
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Have you ever wondered how your local shop gets products delivered from the manufacturer? You walk into your favorite off-road shop at 3 p.m. and order an aftermarket bumper for your new truck. That shop probably doesn’t have the bumper you want just sitting around in its inventory. The clerk says he can have one delivered by tomorrow.

This is where Keystone Automotive Operations Inc. comes into play. Your local shop calls Keystone and places the bumper order. A “pick ticket” is created and sent to its warehouse. Within an hour, a Keystone employee working the warehouse floor pulls the bumper off the shelf and moves it to the loading dock. If your shop is close enough to one of Keystone’s seven warehouses, it gets loaded onto a box truck for local delivery. If not, it goes onto one of Keystone’s semitrucks, which travel daily between its warehouses and “cross docks.” Keystone has 38 cross-docks across the country that do not stock inventory. By noon the next day, your bumper is delivered to the off-road shop and is ready for installation, less than 24 hours after your order.

Keystone is the largest supplier across the country of automotive parts and accessories to thousands of shops. Thanks to a new 450,000-square-foot warehouse in Eastvale, California, parts are being delivered faster than ever. The Eastvale location opened in September 2018 and handles 90,000 orders daily. The warehouse runs the length of seven football fields with 40-foot-tall storage racks. Product comes in on one of 20 dock doors and gets inventoried and shelved. On the other side of the warehouse, employees pick product with small handheld barcode scanners that are connected to Keystone’s exclusive order system. The warehouse currently has $44 million in inventory with a capacity of $70 million. Eastvale is Keystone’s second-largest location.

The building meets California’s LEED standards. The warehouse has lighting zones that shut down when there is no movement. Large energy-efficient fans keep the building cool. Windows are strategically placed to allow natural light in.

An operations manager estimates Keystone saves up to an hour a day moving product in and out of the building. In business, time is money. Keystone does not yet know the cost savings with the Eastvale workflow; however, they will continue to look at strategies to get products out even faster.

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