COURSE OVERVIEW:
Welcome to the Warehousing & Inventory Management for Automotive Parts course. This training has been developed to provide you with the knowledge, systems, and operational strategies required to manage automotive parts storage and distribution efficiently, safely, and accurately.
Warehousing and inventory management are central to the success of the automotive parts supply chain. This course begins by outlining the purpose and scope of warehousing in the automotive context—supporting workshop operations, retail sales, and wholesale distribution. Participants will explore the relationship between stock accuracy, space efficiency, and service delivery performance, as well as the key responsibilities involved in logistics, parts control, and replenishment.
Understanding the classification of automotive parts is essential for effective inventory control. This section introduces the differences between OEM, aftermarket, reconditioned, and used components, and explains how to manage a diverse range of stock—such as fast-moving service parts, slow-moving specialty items, seasonal accessories, and critical repair components. Participants will learn to categorise stock for retail, service, and internal workshop use.
Warehouse layout directly affects operational flow, safety, and productivity. This section explores the core principles of designing a warehouse space, including designated zones for receiving, storing, picking, packing, and dispatching parts. Emphasis is placed on layout optimisation using shelves, bins, and racking systems tailored to the size, frequency, and handling needs of automotive components.
Accurate receiving procedures are fundamental to inventory integrity. This section provides a structured approach to checking deliveries against purchase orders, inspecting for damage or discrepancies, and documenting new stock. Participants will learn how to update inventory records in real-time to ensure accurate data and reduce downstream errors.
Labelling and binning are essential to part traceability and retrieval. This section covers how to create and apply durable part number labels, barcodes, or QR codes; how to allocate parts to specific bin locations and storage zones; and how to organise inventory based on usage frequency, size, and compatibility to streamline access.
Choosing the right inventory system supports consistency and control. This section compares periodic and perpetual stock tracking methods, introduces inventory software and ERP systems, and demonstrates how to use barcode scanners or mobile devices to maintain live, traceable inventory records.
Maintaining appropriate stock levels ensures availability without excess. This section explains how to calculate minimum and maximum stock thresholds based on part usage, lead time, and safety stock principles. Seasonal trends and market conditions are also considered to support responsive inventory planning.
Accurate picking and packing underpin service delivery and customer satisfaction. This section outlines picking processes using paper-based slips or digital devices, and describes efficient order consolidation and safe packing techniques that reduce damage, improve accuracy, and support fast dispatch.
Parts must be issued efficiently to workshop technicians and sales staff. This section focuses on linking parts to job cards and invoices, tracking internal transfers, and ensuring technicians receive required parts promptly to avoid service delays and maximise throughput.
Managing returns, credits, and warranty parts is part of daily operations. This section explains how to process both customer and internal returns, record reasons for return, and manage warranty claims or core returns to suppliers in accordance with documentation requirements and credit procedures.
Stocktakes support system accuracy and financial control. This section introduces strategies for conducting annual, quarterly, or rolling stock counts, reconciling discrepancies, and investigating variances. Participants will learn how to correct records and use count data for forecasting and planning.
Preventing stock loss requires proactive management. This section examines common causes of inventory shrinkage—such as theft, misplacement, and administrative error—and outlines how to implement security protocols, restrict access to high-value items, and use surveillance where appropriate.
Obsolete and surplus stock affects space and capital. This section focuses on identifying aged or slow-moving parts, making informed decisions on clearance or transfer, and avoiding over-ordering of outdated or superseded components through system alerts and supplier communication.
Supplier performance impacts inventory reliability. This section covers how to plan and place replenishment orders using lead time and usage data, manage backorders or urgent needs, and maintain professional communication with distributors and manufacturers to ensure continuity of supply.
Workplace health and safety is a non-negotiable in warehouse environments. This section details safe manual handling practices, the correct use of equipment such as forklifts and ladders, and how to maintain a tidy, hazard-free warehouse layout that supports both efficiency and WHS compliance.
Documentation is critical for traceability and audit readiness. This section explores how to maintain accurate records of orders, receipts, issues, returns, and disposals. It also addresses compliance with warranty tracking and how to use reporting tools for improved oversight and accountability.
Measuring inventory performance helps refine operations. This section introduces key metrics such as stock turnover, fill rate, order accuracy, and carrying costs. Participants will learn how to use system-generated reports to benchmark performance and support strategic decision-making.
Ongoing improvement is essential in warehousing and inventory control. This final section explores how to identify inefficiencies, update procedures, train staff in best practice, and adopt new technologies or layout improvements. The goal is to embed a culture of continuous improvement that adapts to growth, change, and customer expectations.
By the end of this course, you will be equipped with the practical knowledge, inventory tools, and warehousing systems required to manage automotive parts efficiently, reduce stock-related errors, and support fast, reliable service across all areas of automotive retail and workshop operations.
Each section is complemented with examples to illustrate the concepts and techniques discussed.
LEARNING OUTCOMES:
By the end of this course, you will be able to understand the following topics:
1. Introduction to Warehousing and Inventory in Automotive Parts
- Purpose and scope of warehousing in the automotive supply chain
- Relationship between inventory management and service efficiency
- Roles and responsibilities in parts logistics and control
2. Understanding Automotive Parts Categories and Classifications
- Differentiating between OEM, aftermarket, reconditioned, and used parts
- Classifying parts: fast-moving, slow-moving, seasonal, and critical stock
- Managing service parts, accessories, consumables, and bulk supplies
3. Setting Up an Effective Warehouse Layout
- Principles of layout planning for efficiency and safety
- Allocating space for receiving, storage, picking, packing, and dispatch
- Designing shelving and bin systems for optimal accessibility
4. Receiving and Inspecting Incoming Parts Deliveries
- Checking deliveries against purchase orders and supplier documentation
- Inspecting parts for damage, quantity, and specification
- Documenting receipts and updating inventory systems
5. Labelling and Binning Automotive Parts
- Creating and applying part number labels, barcodes, or QR codes
- Assigning stock to bin locations and zones
- Organising stock by size, usage frequency, and compatibility
6. Stock Control Methods and Inventory Systems
- Comparing perpetual (live) vs periodic inventory systems
- Using barcode scanners, inventory software, or ERP platforms
- Updating systems in real-time for accuracy and traceability
7. Setting Minimum and Maximum Stock Levels
- Calculating reorder points based on usage and lead time
- Managing safety stock to avoid stockouts
- Adjusting levels seasonally or in response to market changes
8. Picking and Packing Procedures
- Using pick slips, digital devices, or mobile scanning
- Consolidating orders efficiently for service and retail
- Packing techniques to prevent damage and ensure accuracy
9. Issuing Parts to Service and Sales Teams
- Linking issued parts to work orders or customer invoices
- Ensuring timely supply to technicians and advisors
- Avoiding delays and tracking internal transfers
10. Managing Returns, Credits, and Warranty Parts
- Processing customer and internal returns
- Handling warranty claims and core returns to suppliers
- Recording reasons for return and restocking actions
11. Conducting Stocktakes and Cycle Counts
- Planning annual, quarterly, or rolling stock counts
- Reconciling physical and system quantities
- Investigating variances and updating records
12. Preventing Inventory Shrinkage and Loss
- Securing high-value items and controlling access
- Identifying causes of shrinkage: theft, misplacement, write-offs
- Applying stock security protocols and surveillance
13. Managing Obsolete and Surplus Parts
- Identifying and reviewing aged and slow-moving stock
- Making decisions on clearance, transfer, or disposal
- Avoiding unnecessary purchases of superseded items
14. Supplier Management and Order Replenishment
- Communicating regularly with parts suppliers and distributors
- Using lead time and usage data to plan orders
- Managing backorders, split deliveries, and urgent reorders
15. Workplace Health and Safety in Warehousing Operations
- Manual handling of heavy or awkward parts
- Safe use of ladders, forklifts, and trolleys
- Keeping aisles clear and minimising trip hazards
16. Documentation and Recordkeeping for Inventory
- Keeping logs of orders, receipts, returns, and disposals
- Complying with warranty tracking and audit requirements
- Using reports for decision-making and accountability
17. Measuring Inventory Performance and KPIs
- Monitoring stock accuracy, turnover, fill rate, and carrying costs
- Setting benchmarks for order accuracy and fulfilment time
- Analysing reports to improve inventory decisions
18. Continuous Improvement in Warehousing and Inventory Practice
- Reviewing processes to identify inefficiencies or risks
- Training staff in updated procedures and systems
- Implementing new technologies or layout improvements
COURSE DURATION:
The typical duration of this course is approximately 2-3 hours to complete. Your enrolment is Valid for 12 Months. Start anytime and study at your own pace.
COURSE REQUIREMENTS:
You must have access to a computer or any mobile device with Adobe Acrobat Reader (free PDF Viewer) installed, to complete this course.
COURSE DELIVERY:
Purchase and download course content.
ASSESSMENT:
A simple 10-question true or false quiz with Unlimited Submission Attempts.
CERTIFICATION:
Upon course completion, you will receive a customised digital “Certificate of Completion”.