Smart Bin Automation: Next-Gen Warehousing

Client Snapshot:

A leading $80M Spanish CPG company was facing severe stock-outs despite using SAP and E-Kanban. With a B2B supply chain model and operations heavily reliant on real-time stock updates, recurring inventory mismatches crippled their efficiency. Manual updates, high attrition, and delayed replenishments created supply chain gaps, reducing fulfillment rates. That’s when Total Plant Setup stepped in with Smart Bin Automation—a game-changing solution for inventory accuracy and operational efficiency.

Major Bottlenecks Identified

◾️  18% stock-outs per month despite SAP E-Kanban.
◾️  30% workforce time wasted on manual updates.
◾️  40% mismatch between physical stock and SAP data.
◾️  25% procurement delays due to missing bin-level updates.

Solutions Implemented by total plant setup

◾️  Smart Bins with IoT sensors integrated directly with SAP.
◾️  100% real-time updates using weight/RFID-based triggers.
◾️  Dynamic Min-Max logic replaced manual two-bin system.
◾️  Automated fulfillment workflows reduced order delays by 70%.

Key Results Delivered

✔️  0% stock-outs achieved in 60 days post-implementation.
✔️  99% inventory accuracy sustained over 3 months.
✔️  3X order fulfillment rate, enhancing distributor satisfaction.
✔️  20% labor efficiency gain, lowering attrition and errors.

Ready to eliminate warehouse chaos and reclaim lost profits !

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