SAP YARD LOGISTICS IMPLEMENTATION FOR THE IMPROVED FLOOR TRANSPORT LOAD PLANNING
Zircoo's SAP Yard Logistics solution improved the client's cargo planning and operations.
SAP YARD Logistics Implementation For The Improved Floor Transport Load Planning
Customer:
A large truck manufacturer whose employees daily transport thousands of spare parts on forklifts, from the warehouse to the long conveyor belt, and back.
Challenge:
The customer faced challenges in rapidly resolving incidents such as unavailability of spare parts for shipping and forklift malfunctions. Additionally, they struggled with time-consuming processes for preparing shipping manifests and lacked transparency in monitoring forklift movements.
Solution:
To address these challenges and improve the efficiency of material supply to production lines, the company opted to implement a floor transportation management solution.
Challenge:
Following an in-depth analysis of the client’s internal workflow processes, our team was tasked with implementing, configuring, and customizing the SAP Yard Logistics solution. Additionally, we needed to seamlessly integrate it with other SAP products and third-party software to ensure a cohesive and efficient yard management system.
Project Scope:
1. Integration with Enterprise Resource Planning (ERP):
– Shipment order data is transmitted from the ERP system to SAP YL to establish a logistics plan for forklifts. Additionally, SAP YL receives real-time notifications of manifest documents generated in SAP ERP, creating shipment orders accordingly.
2. Integration with Transportation Management (TM):
– Integration with SAP TM ensures timely loading and unloading of trucks using multiple ramps within a single freight order, enhancing efficiency in transportation logistics.
3. Integration with Third-Party GPS Tracking Solution:
– Integration with the client’s third-party GPS tracking solution enables real-time tracking of transportation unit locations, enhancing visibility and control over logistics operations.
4. Development of Mobile Applications with Xamarin:
– Custom mobile solutions were developed using Xamarin to enhance mobility and flexibility:
– Application 1: For forklift drivers to update task statuses.
– Application 2: For task managers to check-in/out shipment orders and create tasks for forklift drivers automatically.
5. Implementation of New Transportation Unit ‘Tare’ for Accounting:
– Tare registration via orders allows monitoring of workload status in the system for accounting purposes.
6. Building an Application for Vehicle Routes:
– A separate business object was developed to maintain vehicle routes, allowing editing, blocking, and joining of routes in service areas.
7. Algorithm Development for Forklift Assignment:
– An algorithm was devised to assign forklifts to tasks based on drivers’ availability, workload, and real-time location, optimizing task assignment.
8. Route Prompts Display in Mobile Applications:
– Plant’s physical map was digitized to display vehicle routes and recommended sequences in mobile applications for forklift drivers, enhancing training and navigation.
9. Visualization of Transfer Platform with SAP Visual Business:
– Configuration of the plant’s map with SAP Visual Business enables visualization of transfer platforms according to up-to-date positioning of storage bins, improving operational visibility.
10. Workload Planning Report:
– A user-friendly report form was created to display planned orders for specified timeframes, allowing managers to optimize forklift driver distribution within service areas based on workload.
Solution Description:
The solution was designed to address the following challenges:
1. Enhancing Floor Transport Loading Efficiency:
– Tracking and analyzing historical and real-time data regarding forklift operations during shifts.
– Minimizing waiting time during loading/unloading processes.
2. Improving Shipping, Loading, and Unloading Operations:
– Mitigating incidents like material loading delays.
– Facilitating effective coordination between managers and yard workers.
3. Monitoring Task Execution and Vehicle Availability:
– Real-time tracking of vehicle locations.
– Optimization of vehicle routes for efficient operations.
4. Streamlining Operations with Shipping Manifests and Forklift Workflow:
– Electronic manifest creation and maintenance.
– Facilitating seamless communication with yard workers through mobile applications, eliminating the need for phone calls.
The SAP Yard Logistics solution was identified as capable of fulfilling all the aforementioned requirements, providing comprehensive support for optimizing yard logistics operations, enhancing efficiency, and facilitating smooth communication and coordination among stakeholders.
Technology Stack
- ABAP
- BOPF
- FPM
- FBI
- ODATA
- WEB SERVICES
Results:
- Enhanced Yard Management:– The automated yard management solution minimizes unnecessary forklift movements and optimizes routes, reducing vehicle downtime and improving operational efficiency.
- Optimized Task Distribution:– Instead of vehicle downtime or redundancy, the client benefits from optimized task distribution and adherence to shipment plans, ensuring efficient utilization of resources.
- Automated Shipment Transferring:- Integration with ERP and TM solutions streamlines the transferring of shipment orders from third-party systems, enhancing automation and efficiency in logistics operations.
- Incident Management:– Mobile applications handle shipment tasks and promptly notify when repair or assistance is required, ensuring timely response to shipment incidents and minimizing disruptions.
- GPS Monitoring:– GPS feature enables real-time monitoring of shipping to specific destinations, enhancing visibility and control over logistics operations.
- Forklift Selection Optimization:– The ability to select forklifts based on workload and location ensures a systematic and optimized approach to task distribution, maximizing operational efficiency.
- The implemented solution empowers the customer to enhance performance, leading to increased business revenue. Additionally, the client plans to utilize the system for integrating driverless forklifts, further enhancing automation and efficiency in yard management.
