Case study:
How we improved warehouse management and gained control over material flow
Assigned expert
Logistics manager
Challenge
A manufacturing plant was struggling with logistics issues that were affecting day-to-day production. MES and SAP were not properly aligned, warehouse processes lacked structure and material flow was difficult to track.
As a result, inventory accuracy suffered, warehouse operations were inconsistent and many critical processes relied on the experience of individual employees rather than clear standards.
The main challenges included:
- inventory discrepancies across production and logistics operations,
- MES–SAP issues affecting material flow visibility,
- poorly organized production and logistics warehouses,
- missing warehouse zones,labeling and operating standards,
- processes that were not documented or consistently followed.
GQ solution
His role was to understand where the issues were coming from and put the right logistics processes in place so that logistics could support production instead of slowing it down.
Key activities included:
- testing MES–SAP material flows directly on the shop floor,
- mapping processes across production halls,
- reviewing every step of the material flow,
- identifying issues related to NOK part write-offs and production order handling,
- restructuring production warehouses in SAP,
- replacing one shared warehouse with five dedicated production warehouses,
- aligning master data, production orders and Kanban processes,
- completely reorganizing the logistics warehouse, including zoning and visual labeling,
- introducing racking systems and warehouse layout standards,
- creating an internal logistics guide as a single source of truth for the plant.
Result
- full control and visibility over material flow,
- resolution of MES–SAP discrepancies,
- better inventory accuracy and warehouse control,
- clearly defined production warehouses configured in SAP,
- a logistics warehouse ready for audits and customer visits,
- standardized processes across production and logistics,
- clear ownership, responsibilities and logistics rules for all teams.
Strong warehouse management starts with clear processes
This project showed that warehouse management is about much more than keeping a warehouse organized. Reliable data, clear processes and consistent standards make it possible to manage material flow effectively, reduce errors and support production every day.
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