Batch-controlled chemical warehouse with safer putaway

Project overview

A specialty chemical distributor needed a safer warehouse model with stronger segregation rules, clearer batch control, and faster exception handling. The main issue was not whether data existed in the system, but whether warehouse execution consistently followed it.

Challenges

• Incompatible products were sometimes stored too closely
• Batch data was available but not always operationally enforced
• Physical inventory and blocked stock handling required too much manual review

SAP EWM solution design

The SAP EWM design introduced directed putaway, batch-managed inbound checks, storage-type restrictions for incompatible materials, and RF confirmation at movement points. Exception flows for inspection, blocked stock, and relocation were formalized to reduce ambiguity on the floor.

Key outcomes

For a controlled environment like this, 99.5%+ inventory accuracy is realistic, with putaway errors cut by half or more and investigation time reduced significantly. SAP positions EWM around precisely this kind of real-time visibility and execution control.

Next steps

The next phase would be deeper QM integration and automated replenishment for controlled substances.