A leading global manufacturer was struggling with a silent productivity killer: slow, inconsistent, and unsafe pallet picking during production staging. SAP EWM was automatically selecting source HUs and bins—even when those pallets were physically inaccessible.
The result?
- Operators wasting time searching for pallets
- Unnecessary forklift movements
- Re-stacking and re-handling
- Production delays and safety risks
• 42% faster staging cycles
• Zero pallet re-handling
• 100% operator flexibility
• Full pallets only — no partial picks, no confusion
This case study explains the exact configuration, logic, and business impact behind this transformation.
The Business Problem
The manufacturer needed to pick full Handling Units (HUs), each containing 5 EA of product. But SAP EWM’s standard behavior created three major issues:
1. System-selected HU was often physically inaccessible
EWM proposed a specific HU and bin, but in reality:
- The HU might be at the bottom of a stack
- It might be blocked by other pallets
- It might require extra forklift movements
This caused delays, congestion, and safety hazards.
2. Operators needed flexibility
They wanted to pick any pallet that was easiest to access, not the one the system forced.
3. Partial pallets were not allowed
The business required:
- Full pallet picking only
- No partial pallet removal
- No leftover half-pallets in bulk storage
The Goal
The solution needed to ensure:
- WT contains only the storage type (no HU, no bin)
- Operator chooses the HU physically
- System rounds up to full pallet multiples
- No partial pallets are ever picked
Solution Overview
The company implemented a combination of:
- Storage Type configuration
- Warehouse Process Type logic
- Quantity classification
- Pallet-level master data
This created a fully flexible, operator-friendly picking process—without any custom code.
Configuration Breakdown
1. Storage Type Configuration
- Level of Available Quantity = “Storage Bin”
Prevents EWM from drilling down to HU level. - WT Generic = “2 – Only Storage Type”
Ensures WT contains only the storage type—no HU, no bin, no source proposal.
This is the foundation of operator-driven HU selection.
2. Warehouse Process Type (WPT) Configuration
- Round Whole Unit = “4 – Round Up WT Quantity to a Multiple of a Unit”
Ensures full pallet picking only. - Control for HU Pick = “1 – Propose Source HU as Destination HU”
- Select HU Without Storage Process
Allows HU selection without storage process steps.
3. Master Data Requirements
- Product Master: Quantity Classification = “4 – Pallet”
- Pallet AUoM maintained
- Packaging Specification for Pallet
Defines pallet quantity (5 EA) and operative UoM.
How the System Works (Real Example)
Scenario:
- PMR requirement: 8 EA
- Pallet size: 5 EA
System Logic:
- PMR requests 8 EA
- Rounding rule applies → round up to full pallet multiple
- Nearest multiple = 10 EA (2 pallets)
- System creates 1 WT for 10 EA
- WT contains only the storage type
- Operator chooses any 2 pallets
Business Impact
1. 42% Faster Picking & Staging
Operators no longer waste time searching for the “system-selected” HU.
2. Zero Re-Handling
No more rearranging pallets or unnecessary forklift movements.
3. Improved Safety
Less movement = fewer risks.
4. Cleaner Inventory
Full pallets only → no half pallets → predictable inventory.
5. Higher Production Reliability
Staging becomes predictable, fast, and operator-friendly.
Why This Case Study Matters
This configuration is a hidden gem in SAP EWM. Many warehouses struggle with:
- System-driven HU selection
- Partial pallet issues
- Slow staging
- Operator frustration
This solution solves all of them—without a single line of custom code.
Conclusion
By combining:
- Generic WT creation
- Storage-type-only source determination
- Pallet-level quantity classification
- Rounding to full pallet multiples
…the manufacturer transformed its production staging process.
This case study demonstrates how smart SAP EWM configuration can deliver:
- Faster operations
- Higher productivity
- Better safety
- Cleaner inventory
- Happier operators