99.8% Inventory Accuracy and 30% Faster Picking Through SAP EWM on S/4HANA

Company Overview

A leading manufacturer of friction products including brake pads, shoes, and lining, serving a range of vehicle segments. As part of a wider supply chain transformation, the organization set out to modernize and automate warehouse operations across several distribution centres and manufacturing sites.

Before: Manual Warehouse Operations Ahead of a Multi-Site Rollout

• Warehouse operations across four distribution centres and two plants needed to move from manual handling to automated execution.
• The implementation required robust integration with S/4HANA and third-party logistics systems, spanning several different interface technologies.
• Picking efficiency and stock traceability were limited by processes that varied between sites.
• Any cutover carried real risk, since warehouse downtime translates directly into missed dispatch.

The Solution

SAP EWM was deployed on S/4HANA in a decentralized model, incorporating radio frequency frameworks, a material flow system, and custom enhancements. Delivery covered warehouse process blueprinting, EWM configuration, and radio frequency transaction development, followed by system integration testing, user acceptance testing, cutover planning, and hypercare support after go-live. Custom developments, business add-ins, and radio frequency transactions were built for the specific needs of the operation, with both the standard interface and the Fiori app layer used to improve the experience for warehouse users. The material flow system was configured to support automated guided vehicles, conveyors, and pick-to-light systems, with connected device integration included for future readiness.

After: Automated, Accurate, and Fully Traceable Warehouse Operations

• 99.8% inventory accuracy achieved through standardized processes and real-time dashboards.
• 30% improvement in picking efficiency with radio frequency enabled operations.
• 100% automated pallet movements across the sites in scope.
• Zero business disruption during cutover and zero critical defects after go-live.
• Real-time visibility established across warehouse operations.

Efficiency Gains

• 40% reduction in manual effort through integration with S/4HANA and third-party logistics systems.
• Operational costs lowered, with reusable radio frequency and automation templates established for future rollouts.
• Scalable automation templates designed for automated guided vehicles, conveyors, and pick-to-light systems.
• A warehouse framework built to support faster site rollouts and further supply chain innovation.