Project Name
How an Auto Parts Distributor Reduced Stockouts by 40% with Odoo
Our client is a fast-growing auto parts distributor supplying critical components to dealers, service centers, and independent workshops across multiple regions. With a broad catalog of 3,000+ SKUs and increasing daily order volumes, the distributor relies heavily on precise inventory availability to meet customer expectations.
However, inconsistent stock levels, frequent shortages of fast-moving parts, and limited visibility across multiple warehouses were creating serious operational setbacks. These challenges led to delayed deliveries, rising customer complaints, and gradual revenue loss, making inventory optimization a top strategic priority.
The client’s legacy processes and disconnected systems made it difficult to maintain accurate inventory levels across a high-SKU, multi-warehouse distribution network.
- Frequent Stockouts of Fast-Moving Parts: Critical SKUs often ran out because real-time stock levels were not synchronized across warehouses, resulting in delayed deliveries and missed sales.
- Manual and Inconsistent Replenishment: Reordering was spreadsheet-driven with no link to actual demand, SKU velocity, or supplier lead times, causing late purchase orders and irregular replenishment cycles.
- No Centralized Multi-Warehouse Visibility: Each location operated with separate stock records, leading to excess inventory in one warehouse and shortages in another, increasing transfer workload and costs.
- Lack of Demand Forecasting & SKU Classification: The client had no system to analyze historical trends, classify items, or predict seasonal demand, making inventory planning reactive instead of proactive.
- Inefficient Warehouse Operations: Warehouse tasks such as picking and packing were fully manual. With no bin locations or barcode workflows, staff spent excessive time locating items, resulting in slow fulfillment and frequent errors.
- Poor Traceability & Unstructured Storage: High-value auto parts were not tracked through serial/lot numbers, and the warehouse layout lacked proper location hierarchy. This led to misplaced inventory, challenges in managing returns/warranty claims, and inconsistent stock accuracy.
As a trusted Odoo Gold Partner, we implemented Odoo to give the client a unified, real-time inventory management system tailored for high-volume automotive parts operations. Odoo was selected for its robust Inventory, Purchase, and Forecasting modules, along with its flexibility to adapt to multi-warehouse, fast-moving distribution environments. Our team delivered a fully functional Odoo implementation backed by deep supply chain expertise and accelerated decision-making using our flagship product, Dashboard Ninja with AI, enabling instant smart reporting.
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Intelligent Reordering Rules
- Configured min/max levels, safety stock, and vendor lead times to trigger accurate automated RFQs.
- Added custom logic for fast-moving SKUs, ensuring timely replenishment without overstocking.
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Centralized Multi-Warehouse Visibility
- Live, consolidated inventory tracking across all warehouses, enabling the client to instantly view availability, reserve stock, and plan replenishment without manual checks.
- Customized warehouse workflows to match the client’s picking, packing, and internal movement processes.
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Demand Forecasting & SKU Segmentation
- Implemented forecasting tools and item segmentation to classify SKUs by volume, value, and movement.
- Implemented Dashboard Ninja with AI to predict seasonal demand spikes and critical replenishments.
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Barcode-Enabled Warehouse Operations
- Rolled out barcode scanning for receiving, putaway, and picking, reducing manual errors and processing time.
- Structured bin-level locations with optimized routes for smoother warehouse navigation.
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Supplier Performance & Delivery Time Tracking
- Tracked vendor delivery times with automated alerts for delays or inconsistent performance.
- Configured KPIs, including on-time delivery, delivery time variance, and order accuracy, using Dashboard Ninja with AI for instant leadership reporting.
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Real-Time Inventory & Procurement Dashboards
- Used Dashboard Ninja with AI to help the client monitor showcase stock health, fast/slow movers, coverage days, and pending transfers.
- 40% Reduction in Stockouts Across Key SKUs: With automated reordering and demand-driven replenishment, the client drastically reduced part shortages, improving service levels and customer satisfaction.
- 35% Faster Warehouse Operations: Barcode-enabled picking, receiving, and putaway cut manual processing time and eliminated common errors.
- 25% Improvement in Inventory Accuracy: Real-time stock visibility across all warehouses minimized discrepancies and improved planning reliability.
- 30% Reduction in Excess & Dead Stock: SKU segmentation and forecasting helped the client optimize stock levels and avoid over-purchasing slow movers.
- 50% Faster Procurement Decision-Making: Leadership dashboards, powered by Dashboard Ninja with AI, gave managers instant access to supplier performance, stock coverage, and replenishment priorities.
- 20% Better Supplier Reliability: Vendor lead-time tracking and performance alerts improved procurement discipline and supplier accountability.
With our years of experience implementing Odoo for automotive industry, the client transformed an outdated, disconnected inventory process into a unified, intelligent, and fully data-driven ecosystem. With streamlined warehouse workflows, accurate forecasting, and real-time visibility across all locations, the distributor now operates with far greater efficiency and confidence. Our tailored implementation, industry-aligned customizations, and value-added tools like Dashboard Ninja with AI enabled the client to overcome long-standing stock challenges and scale their operations without operational bottlenecks.
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