This isn’t a one-off problem, it’s a daily frustration for warehouse teams across the world. If you’ve ever spent too long searching for a bag of bolts, reordered something you were sure was “somewhere,” or found a crucial item hiding behind a pallet, you’re in good company.
Whether it's screws, sensors, or C-parts the size of your thumb, small items have a habit of vanishing right when you need them most. One moment, they’re neatly stored in bins. The next? They’ve migrated to the wrong shelf, fallen behind racking, or disappeared entirely like they’re part of a warehouse magic act.
The consequences add up fast: slower picking, inaccurate stock counts, wasted space, and frustrated staff. And when a €1 part can halt a €30,000 machine, the cost of poor organisation becomes impossible to ignore.
But there’s good news: there are practical, proven ways to fix it. In this guide, we’ll walk you through five smart strategies to regain control over your small parts and C-parts storage. No gimmicks. Just better systems, improved layouts, and automation that actually works.
Tip 1: Upgrade Your Shelving – Stop Letting Bolts Go AWOL
Let’s start with your shelving. If it’s been the same for years, it’s time to rethink it.
Small parts need a home, not just a home, but the right one: clearly labelled, right-sized, and easy to access. Otherwise, they’ll walk. Or fall. Or end up in a drawer marked “random stuff.”
That’s where purpose-built bin shelving comes in. Systems like Dexion’s Hi280 or Longspan 3 allow you to customise shelves with dividers, bins, and labels, making it easy for your team to store and find exactly what they need.
Why it works:
- Modular design means shelves can evolve with your stock.
- Colour-coded bins support faster visual recognition.
- Clear labelling cuts down on “where’s that part?” guesswork.
Pro tip: Keep fast-moving items at waist height and slower movers higher or lower. Your team will thank you (and save their backs).
“The wrong shelf costs you time. The right shelf saves your sanity.” – Every Warehouse Manager Ever
Tip 2: Use Vertical Lift Machines (VLMs) to Maximise Your Space
Warehouse floor space is valuable, and if you’re like most operations, you’ve used every square metre twice over. So when you can’t build out, build up.
Vertical Lift Machines (VLMs) work like high-rise towers for your inventory. They store trays of small parts vertically and bring the one you need to you, automatically, at the push of a button.
Why it’s a game-changer:
- Up to 85% space savings over traditional shelving.
- 300+ items/hour pick speeds per operator.
- No more ladders or “creative reaching.”
- 99.9% pick accuracy.
In Sweden, one tool distributor used 10 Tornado VLMs to transform their warehouse, handling 100 tonnes of outbound goods daily, all while improving efficiency and control.
At Gonvarri, our GonvaLift and Tornado VLMs are designed specifically for small parts handling. They’re compact, WMS-integrated, and even regenerate energy during operation.
Pro tip: VLMs don’t just store parts, they store data. Sync with your WMS to auto-replenish bins and monitor inventory in real time.
Tip 3: Automate with AS/RS and Shuttle Systems
If your warehouse processes thousands of SKUs or relies on rapid fulfilment, automation is a powerful ally.
Automated Storage and Retrieval Systems (AS/RS); like mini-load cranes or shuttle systems, can store and retrieve totes of C-parts with speed and accuracy, reducing the time your team spends walking or searching.
What you gain:
- Error rates under 0.1%
- Real-time stock visibility
- Lower labour strain
Dexion’s automation tech is scalable and integrator-friendly, meaning it fits smoothly into your current workflows, no heavy disruption required.
Tip 4: Group Like a Pro and Label Everything
Your parts aren’t random, don’t store them that way.
Using ABC slotting, group items based on movement:
- A items: High frequency – store front and centre.
- B items: Medium movers – store mid-level.
- C items: Infrequent – store higher or deeper in.
Add durable labels – or better yet, QR codes – to all bins. Combined with a Lean 5S mindset, this will cut picking errors, speed up scanning, and keep your workspace clean and efficient.
Tip 5: Connect to Your WMS for Total Control
Even the smartest physical systems need a digital brain. Connecting your shelving, VLMs, and AS/RS to a Warehouse Management System (WMS) gives you full control over your small parts inventory.
Benefits include:
- Live stock updates and alerts.
- Automated replenishment.
- Smarter grouping and pick list generation.
Dexion’s solutions integrate with most WMS platforms, giving you real-time visibility and control before small issues become big ones.
Conclusion: Small Parts, Big Impact
They may be tiny, but mismanaged small parts can cause massive disruptions – lost time, wasted money, and frustrated teams.
From smarter shelving and vertical lifts to automation, grouping, and digital integration, these five steps are your blueprint to a more organised, efficient, and scalable warehouse.
Need help redesigning your small parts storage?
We’ve got the products, the experience, and the insight to help you get there.
Let’s make lost bolts and lost time a thing of the past.