Share this case study
Follow us on Linkedin
A large chemical manufacturing site faced severe congestion and inefficiencies due to high volumes of truck traffic handled through manual processes and an outdated yard management system nearing end of support. To address long wait times, limited visibility, and data inconsistencies, the company implemented SAP Yard Logistics as the core platform for a fully automated, future-proof yard. Chosen for its seamless SAP integration, real-time tracking, and ability to connect with automation technologies, the solution was deployed by Westernacher Consulting in a phased approach, starting with a pilot and expanding across multiple sites. Combined with advanced automation for weighing, loading, and driver self-service, the system enabled a 24/7 unmanned yard, significantly improving efficiency, transparency, and scalability.
The challenge: Managing high truck volumes efficiently.
Industrial sites often face intense truck traffic within short time windows. Without automation, this leads to congestion, long waiting times, and data inconsistencies. This was exactly the situation at this one large chemical manufacturing site.
Every day, hundreds of inbound and outbound trucks arrived – often at the same time – transporting raw materials and finished goods. Manual gate check-ins, weighing, and loading processes caused queues that lasted hours. Yard supervisors had limited visibility, and the legacy yard management system could no longer support the growing operational demands. When vendor support for the old system was about to end, the company needed a modern, future-proof solution tightly integrated with SAP logistics.
Project objectives.
The goal was to create a faster, more transparent, and automated yard operation:
- Accelerate truck processing at gates, weighbridges, and loading points
- Reduce manual work for gate and yard staff
- Improve real-time visibility of all vehicles on-site
- Shorten truck turnaround times significantly
- Ensure accurate SAP data through automated postings
Key operational challenges.
Manual gate processes
Truck drivers often waited several hours to enter the site. Manual check-ins and paperwork created critical bottlenecks.
Limited yard visibility
Supervisors lacked real-time insight into truck locations and processing status, making coordination difficult.
High error risk
Manual data entry during weighing and loading led to frequent inconsistencies between yard and logistics data.
Long on-site times
Poor coordination meant trucks stayed on-site far longer than necessary, increasing costs and delaying deliveries.
Weak system integration
The legacy yard system was not fully aligned with SAP backend processes, causing data mismatches.
Why SAP Yard Logistics?
The company selected SAP Yard Logistics (SAP YL) as the foundation for its digital yard because it:
- Integrates natively with SAP logistics processes
- Manages all yard activities from entry to exit in one system
- Provides real-time tracking of truck movements
- Connects with automation technologies such as weighbridges and kiosks
Offers 3D visualization for improved monitoring and planning
SAP Yard Logistics provided a scalable platform that could support long-term growth and full yard automation.
The Solution: A fully automated, unmanned Yard.
Westernacher Consulting implemented SAP Yard Logistics together with advanced automation software. The project started with a pilot at selected plants to validate the approach and deliver fast results. After a successful pilot, the solution was rolled out step by step across additional sites.
SAP Yard Logistics manages transportation units, yard orders, and statuses, while the automation layer handles physical processes such as weighing, loading, and self-service driver interaction. The result is a 24/7 unmanned yard, where trucks move independently without manual support.
How the automated yard works.
Self-service truck check-in
Drivers register at kiosks on arrival. SAP Yard Logistics verifies the data, assigns parking, weighing, or loading locations, and captures a digital signature. Gate processing time dropped from minutes to seconds.
Automated weighing
Inbound and outbound weighbridges record weights automatically and send the data directly to SAP YL in real time. Manual entry errors were completely eliminated.
SAP-integrated loading
Loading activities are aligned with SAP delivery documents. Quantities and statuses update automatically, ensuring full data consistency.
Digital check-out
After loading and final weighing, drivers confirm digitally. SAP Yard Logistics prints exit documents, updates transport status, and authorizes departure without manual intervention. Truck turnaround time fell from hours to just minutes.
With built-in 3D yard visualization, supervisors can monitor every step in real time and proactively prevent congestion.
Measurable business results
- 70% faster truck turnaround times, enabling over 3x more daily deliveries
- Near-zero data errors, down from 5% shipment discrepancies
- 50% reduction in idle time thanks to full yard visibility
- 20% lower operational costs through reduced manual effort and delays
KPIs are indicative and may vary depending on site infrastructure and operating conditions.
Why Westernacher Consulting?
Successful yard automation requires more than software. It takes deep knowledge of yard operations, SAP logistics, and industrial processes. Westernacher Consulting combines more than 30 years of SAP expertise with hands-on industry experience gained from similar yard transformation projects worldwide.
From assessment and design to implementation, go-live, and optimization, Westernacher Consulting helps organizations build yards that operate faster, safer, and with significantly less manual effort.
Ready to modernize your yard?
If truck queues, manual yard work, or limited visibility are slowing down your operations, it may be time to transform your yard.
Westernacher Consulting can help you define a clear roadmap toward an efficient, automated yard powered by SAP Yard Logistics.
