Project Overview

In November 2024, Scoptis partnered with VDL Bus & Coach to address significant logistical issues following the company’s move to a new manufacturing facility. While the previous factory had ample storage space, allowing early deliveries, this led to overstocking and disorganized inventory. The shift to the new location exposed deeper inefficiencies in warehouse management.

With over 3,000+ individual parts sourced from 1,800+ suppliers to assemble a single bus, even a shortage of just 100 components could stall production for days, costing valuable time and resources.

About the Companies

Scoptis: Is a dynamic technology solutions provider specializing in supply chain digitization, custom software development, and process automation. With a hands-on, agile approach, Scoptis delivers scalable and tailored solutions that streamline logistics and production workflows for manufacturing and logistics-intensive industries.

VDL Bus & Coach: A part of the Dutch industrial conglomerate VDL Groep, is a leading European manufacturer of public transport solutions, including city buses, coaches, and electric vehicles. Renowned for its innovation and commitment to sustainability, VDL plays a key role in shaping the future of public mobility across Europe and beyond.

Key Problems Identified

• Overstocked Inventory: Articles were left scattered around the factory due to insufficient storage planning.

• Delivery Issues: Inconsistent and unscheduled deliveries from suppliers disrupted the workflow.

• Production Delays: Missing critical parts delayed entire bus assembly lines.

• Unorganized Inventory Handling: Manual and inconsistent use of materials hindered stock tracking and cycle counting.

• Lack of Supplier Communication: Resulted in over- or under-stocking key components.

Project Challenges

• Data Inconsistency: VDL provided limited initial data. Package labeling standards, location naming, and warehouse zoning had to be designed from scratch.

• Human Resource Gaps: The warehouse was understaffed, with minimal training provided to existing employees.

• Limited Development Bandwidth: Initially, only one developer (from Scoptis) managed the entire development scope.

• Frequent Process Changes: The evolving nature of the new factory required constant adjustments, making system design iterative and often frustrating.

Solutions & Achievements

• Scanner Integration (Powered by Lobster): Scoptis introduced a scanner-based system allowing operators to efficiently log and track items through barcode scanning, improving traceability and reducing human error.

• Warehouse Management System (WMS) Implementation

A customized WMS was developed with the following key modules:

• Goods Receiving: Arrival files now inform operators about incoming shipments. The system verifies the quantity and accuracy of articles received.

• Movement Tracking: Once articles are received and labelled, operators use scanners to place items in designated storage areas—ensuring accurate location tracking.

• Task Management: Designated operators receive dynamic pick lists for production. The system guides them to exact article locations, ensuring production lines stay supplied.

• Full Warehouse Labelling: Every location, box, pallet, and package was labelled, allowing precise tracking of over [insert number] inventory items.

Proven Results

Since the implementation of Scoptis’ system, VDL has achieved:

• 85% Reduction in Inventory Misplacement

• 40% Faster Article Retrieval for Production Tasks

• 30% Improvement in Receiving Time per Truckload

• 25% Increase in Supplier Delivery Accuracy

• 70% More Accurate Stock Counts

Conclusion

The partnership between Scoptis and VDL turned a chaotic post-move scenario into a digitally enabled, efficient, and scalable warehouse operation. With smart technology integration and real-time visibility, VDL is now better equipped to manage its complex supply chain and meet growing production demands without disruption.