Case Study: Company Success Using Barcode Scanning in a Yard Environment
Implementing barcode scanning in warehouses has become standard in many industries—but in yard-based operations, especially those handling building materials, adoption has lagged. Why? Outdoor conditions, oversized inventory, and manual workflows make traditional scanning systems seem impractical.
But when done right, barcode scanning can dramatically improve accuracy, accountability, and efficiency—even in rugged, open-air environments. Here’s a look at how one building materials distributor successfully implemented barcode scanning in their yard—and what your operation can learn from their journey.
The Challenge: Disorganized Yard, Missed Materials, and Delivery Delays
Before implementing barcode scanning, this distributor—a mid-sized regional supplier of concrete, lumber, and bulk insulation—was struggling with:
Frequent picking errors in the yard
Inaccurate inventory counts between warehouse and outdoor stock
Lost or misplaced materials during staging
Delivery delays due to incorrect or incomplete orders
Yard staff relied heavily on printed pick lists, visual identification, and verbal instructions—all of which broke down under pressure, especially during peak season.
The Goal: Real-Time Accuracy Without Slowing Down the Yard
The company wanted a system that could:
Improve pick and stage accuracy
Provide real-time inventory updates
Be used by forklift operators and yard workers on the move
Work in harsh, outdoor conditions
The Implementation: Barcode Scanning + ERP Integration
Working with their ERP provider, the company deployed a mobile barcode scanning solution that integrated directly into their existing system.
Key Steps:
SKU Tagging:
All inventory, including oversized items, was labeled with weather-resistant barcode tags—either directly on product packaging or on pallet-level signage.
Mobile Device Rollout:
Yard staff were equipped with rugged mobile scanners and tablets capable of syncing with the ERP in real time—even with intermittent internet access.
Digital Pick Tickets:
Printed pick lists were replaced with ERP-generated digital pick orders, accessible on handheld devices.
Staging Verification:
As items were staged, they were scanned and marked as “ready” in the ERP—allowing dispatch to view order status instantly.
The Results: Faster, Smarter Yard Operations
Within three months of implementation, the distributor saw:
92% reduction in picking errors
Delivery delays dropped by 43%
Full inventory visibility, including staged and in-transit goods
Improved job satisfaction among yard staff, who had clear digital workflows
Lessons Learned
Outdoor barcode scanning is possible—with the right materials and mobile tech
Staff training and process standardization were critical to success
ERP integration made scanning useful—not just cosmetic
The return on investment was visible within the first quarter
📲 Interested in barcode scanning for your yard? Let’s show you how it can work in your environment.
