MRO and spare parts inventory plays a critical role in keeping operations running. Whether supporting technicians, branch locations, repair shops, or maintenance teams, these environments often need fast access to thousands of parts that may move unpredictably and remain in inventory for years. That creates a unique storage challenge.
Most MRO environments manage a mix of:
- Slow-moving inventory
- Critical replacement parts
- Emergency fulfillment requests
- Long-tail SKU growth
- And space constraints that continue to increase over time
At the same time, not every MRO operation is a strong fit for AutoStore. The real question is not:
“Can AutoStore support MRO inventory?” It is:
“Which MRO applications actually justify an AutoStore system?”
Because MRO is not one single workflow. Some operations require dense, high-SKU spare parts storage with fast retrieval and high throughput, while others may be better suited for solutions like Vertical Lift Modules (VLMs) or traditional storage systems.
In this article, we’ll look at where AutoStore works particularly well within MRO and spare parts environments, where it may not be the right fit, and the types of operations that typically benefit most from high-density goods-to-person automation.
For a deeper overview of the technology itself, read What is AutoStore – Everything You Need to Know
Where AutoStore Works Best in MRO Inventory
Let's take a look at the applications where AutoStore would work in an MRO operation, and later on, we will discuss where AutoStore is not a good fit.
High-SKU, Small Spare Parts Environments
AutoStore really shines in environments with large numbers of SKUs, especially small to medium-sized parts. This is incredibly common in MRO.
If you are supporting equipment that is 10, 15, or even 25 years old, those parts do not go away. They sit in your inventory, sometimes untouched for long periods, but still need to be available the moment something breaks.
At the same time, new equipment continues to be introduced, which means new SKUs are constantly being added. Over time, that creates a long-tail inventory problem that is difficult to manage with traditional storage.
This is where AutoStore becomes valuable. It allows you to store a high volume of SKUs in a compact footprint while keeping everything organized and accessible. Instead of slow-moving parts taking up valuable space on shelving, they are stored efficiently without sacrificing retrieval speed.
When Storage Density Becomes a Constraint
Most MRO operations eventually run into a space problem. Inventory keeps growing, but the building does not.
You start adding shelving, adjusting layouts, or storing items in less-than-ideal locations just to make everything fit. Over time, that leads to inefficiencies that impact both storage and fulfillment.
AutoStore changes that dynamic by using high-density storage to maximize the available footprint. Rather than expanding the facility or continuing to add low-density storage, you are able to reclaim space and support ongoing SKU growth within the same environment.
Labor-Constrained Environments
We’ve found that many warehouse operations struggle to compete for labor with higher-paying industries like oil, where wages can be significantly higher than typical warehouse roles.
AutoStore helps address this by reducing the amount of manual effort required to manage inventory. Operators are no longer walking long distances or searching for parts. Instead, the system delivers items directly to them, increasing productivity and allowing teams to handle more volume with fewer resources.
For a broader look at MRO inventory optimization strategies, read MRO Inventory Optimization.
Common MRO Inventory Stored in AutoStore
AutoStore is best suited for small to medium-sized spare parts and maintenance inventory that can be stored efficiently within bins. Examples include:
- Bearings
- Sensors
- Fittings
- Fasteners
- Hardware
- Electrical components
- Relays
- PLC components
- Fuses
- Valves
- Hoses
- And others
AutoStore Bins inside the Grid containing electrical components and wire bundles
Inventory better suited for other storage systems may include:
-
Large motors
- Heavy assemblies
- Palletized inventory
- Long or oversize parts
- Bulky tooling
- Irregularly shaped components
Industries Where AutoStore Fits Well for MRO
AutoStore is a great fit for certain MRO applications, not all. Here's where it is most effective.
Heavy Equipment Dealers
Heavy equipment dealers often support equipment that has been operating in the field for decades. That creates extremely large spare parts inventories with ongoing SKU growth. Typical inventory may include:
- Filters
- Hydraulic fittings
- Sensors
- Engine components
- Maintenance kits
- Service parts
- Fasteners
Industrial MRO Supply
Industrial MRO supply operations often manage extremely high SKU counts across a broad range of replacement parts and consumables that support maintenance and repair activities across multiple facilities or customers.
Typical inventory may include:
- Bearings
- Electrical components
- Pneumatic fittings
- Hydraulic components
- Repair kits
- Fasteners
- Conveyor spare parts
- Maintenance consumables
Centralized Spare Parts Distribution
Many organizations consolidate spare parts inventory into centralized distribution facilities that support multiple branches, facilities, technicians, or maintenance operations from a single location. Examples may include:
- Industrial service providers
- Equipment or facility maintenance providers
- Regional maintenance support hubs
- Aviation and aerospace spare parts
- Automotive parts distribution
Common MRO Workflows Supported by AutoStore
Branch Replenishment
Branch replenishment workflows are unique because inventory is often allocated across dozens or even hundreds of branch locations, each carrying different inventory profiles, stocking levels, and demand patterns. For operations supporting large branch networks, the challenge is less about bulk fulfillment and more about efficiently picking and consolidating thousands of low-volume spare parts orders across a constantly expanding SKU base.
Technician Will-Call
One area where AutoStore becomes especially impactful is in will-call or on-demand scenarios. Think about a technician who arrives needing a part immediately. They are not waiting around while someone searches through shelving or checks multiple storage areas. Every minute matters because it directly impacts uptime.
AutoStore enables fast, consistent retrieval, and when paired with software like Kardex FulfillX, it allows you to prioritize urgent orders and move them to the front of the queue. That means parts can be retrieved within minutes without disrupting the rest of the operation. So if your operation regularly deals with urgent, walk-in, or time-sensitive requests, this is where AutoStore delivers real value.
Repair Shops
Many MRO operations must support internal repair shops, engine rebuild operations, or service bays that rely on fast access to spare parts throughout the day. In traditional storage environments, technicians and operators often spend significant time walking between shelving locations, searching for inventory, or waiting for parts to be retrieved manually. With AutoStore, inventory is centralized and delivered directly to the operator or technician when needed. This helps reduce search time, improve inventory organization, and support faster repair workflows without requiring large amounts of floor space for spare parts storage.
Real-World Example: MRO Inventory at a Caterpillar Dealer
We see this play out in real operations all the time.
In one case, we worked with a large Caterpillar dealer that was building a new greenfield facility. The goal was to bring multiple functions into one location, including:
-
A storefront for will-call
-
An engine repair shop
-
A centralized distribution hub supplying parts across their network
So the challenge wasn’t just storage. It was how to support multiple workflows, all pulling from the same inventory, within a single operation. At the same time, they were dealing with the realities of MRO. Supporting equipment that had been in the field for decades, while continuing to add new SKUs. Inventory kept growing, but space didn’t.
This is exactly where AutoStore proved to be a strong fit.
By consolidating the majority of their spare parts into a high-density, goods-to-person system, they were able to simplify fulfillment, reduce manual consolidation, and support both distribution and will-call workflows more efficiently.
For a deeper look at how this works in Caterpillar dealer environments, see how AutoStore integrates with WMS systems in this example.
When is AutoStore NOT the Right Fit for MRO?
At the same time, it is important to understand what typically does not fit well within AutoStore. Inventory better suited for other storage systems may include:
Large, Heavy, or Irregular Parts
If your inventory includes large components, bulky assemblies, or irregularly shaped items, AutoStore is not designed to handle those effectively. These types of parts are better suited for other storage systems, such as VLMs or pallet-based storage. Learn more about types of automated storage for MRO inventory optimization.
Low-SKU and Low-throughput Environments
If you are working with a relatively small number of SKUs and low throughput, AutoStore may be more than you need. In these cases, simpler storage solutions can often meet operational requirements without the added investment.
Line-Side Manufacturing (By Itself)
AutoStore fits best in applications that have, in general, more than 2,000 picks per day. In manufacturing environments where the primary goal is simply storing emergency spare parts for line-side support, there is often not enough throughput to justify an AutoStore. Instead, I'd recommend a Vertical Lift Module. However, if you want to consolidate line-side manufacturing, technician will-call pickup, and regional spare parts distribution into one system, that would be a much more compelling case for AutoStore.
How AutoStore Fits Into a Broader MRO Strategy
In most real-world MRO environments, AutoStore is not a standalone solution. It becomes the core system for managing high-SKU, small parts inventory, while other systems support different needs.
For example, AutoStore might handle the bulk of spare parts, while VLMs are used for tools or irregular items, and carousel systems support fast-moving consumables.
The goal is not to force everything into one system. It is to align each type of inventory with the solution that handles it best, creating a more efficient and scalable operation overall.
Key Takeaway
AutoStore is best suited for high-SKU, small-part, time-sensitive MRO inventory, where there are generally more than 2,000 pick tasks per day.
It is particularly effective in environments that require:
- Rapid retrieval of critical spare parts
- Efficient management of long-tail inventory
- High-throughput picking for distribution and replenishment
- Support for will-call and on-demand fulfillment workflows
AutoStore is not designed for large, bulky, or irregular parts. It is most effective when it's utilized as part of centralized spare parts distribution process which usually services multiple distribution or picking workflows at once (i.e. line-side repair, branch fulfillment, counter pick-ups, etc.)
FAQs
Is AutoStore good for MRO inventory?
Yes, AutoStore is highly effective for MRO and spare parts environments with high SKU counts, small parts, and time-sensitive retrieval needs.
What types of MRO parts can AutoStore store?
AutoStore is best suited for small to medium-sized spare parts that can be stored in bins. Larger or irregular items are typically handled outside the system.
How does AutoStore handle slow-moving inventory?
AutoStore uses dynamic slotting, where slow-moving parts naturally settle deeper in the system while frequently picked items stay more accessible.
Can AutoStore support will-call or urgent orders?
Yes, when paired with software like Kardex FulfillX, AutoStore can prioritize urgent orders and support on-demand retrieval workflows.
