PACCAR Parts
Spring 2026
Mississauga Ontario
Paccar Inc, A global leader in Class 6, 7, and 8 trucks—operates PACCAR Parts, its aftermarket division responsible for supplying parts to dealerships worldwide. Facing increasing pressure to improve workplace ergonomics while maintaining productivity, the organization launched an initiative to modernize its order picking process.
Platform
weeks
%
Reduction in Warehouse travel
The Challenge
PACCAR Parts, the aftermarket division of PACCAR Inc., set a hard constraint tied to its 2030 goals: no employee lifting over 35 lbs.
The existing picking process wasn’t designed for that reality.
Operators used reach trucks to retrieve heavy truck parts, moving each pick back to the shipping dock and repeating the cycle after just one or two items. The result was a process defined by movement, not flow.
This created three structural issues:
- Excessive travel in every pick cycle
- High physical strain from repetitive heavy handling
- A multi-operator workflow that didn’t scale
The requirement was non-negotiable: improve ergonomics without reducing throughput.
The Solution
After identifying the issue and performing internal trials led by PDC Manager Scott Tipping, PACCAR Parts partnered with Carney to re-engineer the pick cycle at the point of interaction.
The solution integrated a custom Carney picking platform, a Crown PE 4500 tow platform, and a TAWI mobile vacuum lift system into a single, purpose-built heavy-parts picking unit.
The all black custom picking platform measured at 124″ long, 49″ wide and 10″ high with a capacity of 1,500 lbs. The platform was designed to fit directly onto the PE 4500 to increase capacity, reduce motion and increase controlled load density.
The last piece of the order picking puzzle this picking unit resulted in many measurable system changes including:
- Consolidated picking for up to 16 customer orders per cycle
- Elimination of repeated transport between storage and dock
- Integrated ergonomic lift assist at point of pick
Implementation took just over two months, with iterative refinement to ensure throughput parity throughout deployment.
The Results
The system replaced movement with density.
By collapsing pick cycles and eliminating redundant travel, PACCAR Parts achieved a measurable shift in warehouse performance without compromising safety or output.
- Full ergonomic compliance (≤35 lbs per lift)
- 94% reduction in travel between storage and shipping dock
- Reduced manual handling exposure and operator strain
- Higher load density per trip via stable multi-pallet transport
A non-slip, lipped-edge platform enabled secure side-by-side pallet transport, allowing operators to move more product in a single controlled cycle.
PACCAR Parts didn’t just balance ergonomics and productivity.
They redesigned the system so the tradeoff no longer existed.
Carney did a great job working with us on a process that we had to become more efficient in. They came out and worked with us real close, we got the solution that we needed and everything turned out great.