Manufacturing Plant Parts Inventory

One of the world’s largest automotive manufacturers that designs, manufactures, markets, and distributes vehicles and vehicle parts required the support of RGIS. The company manufactures vehicles in several countries, employing 212,000 people and conducts business in more than 140 countries.


One of the world’s largest automotive manufacturers had lost confidence in the internal parts stock at one of the manufacturing plants, so required RGIS to provide the following:

  • A wall-to-wall inventory of the facilities that included:
  • Two large-scale supply warehouses
  • 750,000 sq. ft. assembly plant
  • As the plant was not able to shut down, the inventory could not impact the production schedule


The automotive manufacturer partnered with RGIS to complete the wall-to wall warehouse parts count, and RGIS provided the following:

  • The automotive manufacturer’s inventory managers and RGIS worked together as one team
  • Planned a one-day Saturday inventory, which allowed them to maintain the existing production schedule
  • An RGIS team of 673 experienced management and team members were deployed across all three facilities
  • Ensured the plant would remain open during the inventory


The automotive manufacturer found by outsourcing the wall-to wall warehouse parts count to RGIS, the following was achieved:

  • In one 24 hour period, the team inventoried more than 27.5 million pieces
  • The customer received a completed inventory file from RGIS
  • The production management system was up to date by noon on Sunday, in time to resume production as scheduled
  • All buildings were completed on time
  • The parts inventory could now be trusted due to the accuracy