Pallet-flow warehouse optimization in industrial manufacturing

Project overview

A manufacturer shipping both full and mixed pallets needed better forklift productivity and stronger visibility into pallet movement. Internal movement was happening, but not always with enough real-time control.

Challenges

• Forklift movement lacked real-time transparency
• Pallet confirmation discipline varied by shift
• Staging lanes became congested before dispatch peaks

SAP EWM solution design

The SAP EWM approach emphasized directed pallet movement, RF confirmation, route-based staging, and analytics around internal traffic patterns. The design aimed to improve both physical throughput and management visibility.

Key outcomes

Public industrial examples show pallet-per-hour gains around 30% in well-controlled environments. That supports an indicative improvement range of 20% to 30% here, together with much tighter stock confidence in controlled lanes.

Next steps

The next phase would be forklift telemetry and queue monitoring at staging lanes.