Case study: How IPISPL Improved Efficiency by 35% With Smart Yard Management For A Client
- Shraddha Srivastava
- Nov 20
- 5 min read
Introduction: Turning a Crowded Yard into a Model of Efficiency
One of India’s top farm and construction equipment manufacturers was producing machines at record speed. Every month, hundreds of tractors and construction units rolled out of its plant, ready for dispatch across India and beyond.
But behind the production success was a growing problem. Once the machines reached the storage yard, operations slowed down. Movement tracking was manual, layouts were unclear, and communication between the warehouse and dispatch teams often caused confusion.
Every delay affected production flow and on-time deliveries. What the company needed was not more manpower, but a system that brought structure, safety, and visibility to its yard operations.
That’s when IP Integrated Services Pvt. Ltd. (IPISPL) was brought in. Within a year, IPISPL helped transform the manufacturer’s crowded, paper-driven yard into a smart, data-enabled operation that improved efficiency by over 35 per cent and achieved 100 per cent on-time dispatch performance.
The Challenge: Managing Growth with Limited Visibility
The yard handled large volumes of machines, but lacked an organized system to manage them effectively. The problems were familiar to many manufacturers in India:
Machines were parked randomly, blocking pathways.
Manual tracking created errors and delays.
Safety procedures were inconsistent.
Dispatch teams struggled to locate and move units on time.
As the company’s production increased, space utilization dropped and operating costs climbed. What once worked for a smaller operation could no longer sustain large-scale manufacturing.
The Partnership: Combining Japanese Precision with Indian Expertise
The farm and construction equipment manufacturer partnered with IPISPL, a joint venture between Itochu Group (Japan) and Parekh Integrated Services (India). The mission was simple yet ambitious:
Create a yard that operates with the same precision, speed, and safety as the assembly line inside the plant.
The First Step: Understanding the Yard
IPISPL began with a deep-dive assessment. Over several weeks, the team mapped every movement, analyzed traffic patterns, and documented operational delays.
The study revealed that the existing system was almost entirely manual. Yard space was underutilized, and retrieval times often exceeded 45 minutes per unit.
Armed with data, IPISPL designed a customized yard improvement plan built on structure, technology, and process discipline.
The Transformation Plan: Six Pillars of Smart Yard Management
IPISPL’s solution revolved around six key areas, each addressing a specific challenge.
Resource Optimization: Matching manpower, handling equipment, and vehicles to daily operational demand improved productivity by 20 percent.
Training and Skill Development: Operators and supervisors were trained in safety protocols, digital tools, and 5S practices to build a skilled and accountable team.
Technology Enablement: A Warehouse Management System (WMS) was introduced to digitize every yard movement. Each machine received a unique barcode or QR tag for real-time tracking.
5S and Kaizen Practices: The yard was reorganized using Japanese lean management principles. Zones were clearly marked, storage spaces were optimized, and workflow paths were defined.
Performance Monitoring: IPISPL implemented measurable Key Performance Indicators (KPIs) for on-time dispatch, retrieval time, and space utilization.
Streamlined Communication: Clear reporting lines and coordination between warehouse, logistics, and transport teams reduced delays caused by miscommunication.
Building a Culture of Safety
When IPISPL took over, safety was viewed as an obligation. Within months, it became a core part of the yard’s culture.
Regular fire and electrical audits, mock drills, and refresher training sessions were conducted. Fire extinguishers and safety signage were standardized, and emergency exits were clearly marked.
The result was a yard where every worker understood their role in maintaining safety and operational excellence.
Organizing the Space: Applying the 5S Model
IPISPL redesigned the entire yard using 5S principles, Sort, Set in Order, Shine, Standardize, Sustain. Machines were grouped by model and stored in zones labeled A to S. Display boards and directional signage simplified navigation, while open driveways prevented congestion.
For the first time, teams could locate a specific machine within 10 minutes, compared to nearly an hour before. Space utilization rose from 70 percent to 95 percent, turning the yard into an organized, efficient environment.
Technology as the Turning Point: The Power of WMS Integration
The biggest breakthrough came with Warehouse Management System (WMS) integration. This digital platform connected every movement inside the yard with the company’s internal ERP system.
Key improvements included:
Barcode-based machine tracking for real-time visibility.
Automatic data exchange (EDI) between WMS and ERP to eliminate paperwork.
Digital dashboards for monitoring location, status, and inventory aging.
Instant alerts for movement delays or exceptions.
This integration gave managers a live view of every machine’s journey, from arrival to dispatch, improving traceability and accountability across operations.
Driving Efficiency: Dock Scheduling and Load Planning
To further streamline operations, IPISPL implemented dock scheduling and load sequencing tools. Machines were arranged based on dispatch priority, route, and available truck capacity.
This reduced loading time, minimized vehicle idle hours, and improved turnaround efficiency by 25 percent.
The system’s precision allowed dispatch teams to coordinate directly with production schedules, ensuring zero bottlenecks.
The Results: Efficiency You Can Measure
The transformation delivered measurable improvements across all key performance areas:
Metric | Before IPISPL | After IPISPL Intervention |
Yard Organization | Manual and unstructured | 5S-zoned, well-defined layout |
Tracking System | Paper-based logs | Digital WMS with real-time visibility |
Machine Retrieval Time | 45–60 minutes | Under 10 minutes |
Space Utilization | ~70% | 90–95% |
Safety Compliance | Inconsistent | 100% audit-ready |
On-Time Dispatch | 65–70% | 100% |
With a fully optimized fleet and streamlined milk-run operations, the yard now functions as a benchmark for smart yard management in India.
Why It Worked
The success of the transformation lay in integration.
By aligning technology, process improvement, and people, IPISPL turned a high-volume, high-pressure environment into a model of control and coordination.
The WMS brought digital accuracy.
The 5S model brought structure.
And regular reviews kept performance consistent.
Together, they created a yard that was not only efficient but also scalable and sustainable.
Conclusion: When Logistics Reflect Manufacturing Excellence
This case study shows how structured yard management and WMS integration can redefine efficiency for large-scale manufacturers.
Through IPISPL’s data-driven logistics approach, the farm and construction equipment manufacturer’s yard evolved from a storage space into a strategic supply-chain hub that drives productivity, safety, and growth.
For India’s manufacturing sector, it proves a powerful point:
The smarter your logistics, the stronger your production.
If your manufacturing yard struggles with visibility, disorganization, or rising costs, it’s time to act.
IP Integrated Services Pvt. Ltd. (IPISPL) specializes in yard management in India, warehouse management system (WMS) integration, and industrial logistics solutions designed for manufacturing environments.
Partner with IPISPL to transform your yard into a smart, efficient, and safe operation that delivers measurable results.
Let’s create your next yard success story, together.
Email: customerservice@ipispl.in
Contacts: +91-124-4224834
+91-124-4224835
+91-124-4224836
+91-124-4224837
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