Packing and loading optimization in the construction industry

When we marvel at ancient constructions, we wonder how it was possible for humans to build such structures in the past. Today, our landscapes are filled with equally impressive buildings, many of which were built with equipment provided by Layher. “More possibilities” is Layher’s brand promise. The German company is a leading global manufacturer of scaffolding systems, ladders and protective systems.

Tackling planning hurdles with software integration

At Layher, five dispatchers plan domestic and international transports from a central distribution location. These transport planners are tasked with monitoring two shipping points. Up to 90 vehicles are loaded with scaffolding systems and other construction equipment to service customers on a daily basis. Forwarding agencies carry out the transport.

Layher was looking for a packing and loading optimization solution that could be integrated with their SAP ERP. A standardized user interface was required, which made it necessary to replace their Windows-based planning tool. With an eye on the future, they sought to reduce, and ideally eliminate, maintenance costs for the various interfaces. The goal was to integrate the software with SAP to make the company’s logistics planning more transparent by using standard SAP Sales Orders and Stock Transfer Orders.

The software had to handle Layher-specific document types, such as rental contracts. Another key requirement, from a logistics point of view, was to have planning flexibility at the SAP line item level. It was critical for Layher to have options to flexibly adapt the amount in the line or manually determine the stop sequence. The software should likewise be designed to support transport planners in their daily processes of generating transport orders, full capacity truck loads and optimized routes. Moreover, they wanted to visualize planned and optimized loads in a user-friendly dashboard. Lastly, Layher was looking to transfer planning results to their existing warehouse system and get quick insight into optimization results.

A streamlined planning process

“We are very enthusiastic about the software solution that ORTEC offers. The goals that we set were met in full and the collaboration was goal-oriented at all times. We look forward to cooperating with them further.” – Patrick Reiner, Logistics Manager at Layher

Layher chose ORTEC for SAP ERP to facilitate load building for cartons, pallets, trucks and containers as well as optimal route scheduling. Our O4S Transport Load Optimizer and its modules for packing and loading optimization were implemented and rolled out with the organization’s SAP ERP.

Users work directly in the standard SAP environment and plan their daily transports with our solution. Our SAP-integrated software for packing and loading optimization supports Layher in its distribution planning by allowing for flexible planning at the line item level while taking Layher-specific loading rules into account. Transport planners can adjust the loading proposal by adding or removing line items where necessary, and can decide to approve planned tours on an individual basis. 3D visualization also allows them to automatically create optimally loaded trucks. The final optimized results are available immediately and can be easily communicated and shared.

Planning flexibility and efficiency improves service reliability

Thanks to ORTEC for SAP ERP, Layher benefits from optimized tours with vehicles and containers loaded to full capacity. The result is heightened planning security. Our solution has increased delivery reliability and dependability. It has decreased transport and logistics costs and supports the dispatchers quickly and efficiently in their daily work.

With centralized planning in place, Layher no longer struggles to coordinate between sales, distribution, freight and purchasing departments. Every valuable bit of information is easily exchanged and shared with customers and forwarding companies.