Automating Holcim Philippines's bulk material logistics with VAS yard management

Holcim Philippines faced significant operational inefficiencies in their yard management processes that were impacting their overall productivity and cost-effectiveness. The existing LAN backbone and slow internet connectivity created bottlenecks in data transmission and system performance, hindering efficient operations. Their high reliance on manual processes for weighing and logistics tracking resulted in increased operational costs and introduced the potential for human errors throughout the workflow.

The lack of precise time measurements across different process steps made it difficult for Holcim Philippines to analyze delays and identify inefficiencies in their logistics operations. Additionally, scale staff were tied up with repetitive administrative tasks instead of focusing on higher-value activities that could better serve customers and improve business outcomes.

Each weighing process required 2-3 minutes per truck, resulting in approximately five hours of processing time for 100 trucks. Manual data entry frequently led to errors in Delivery Receipts (DRs) and inaccurate weight records, while shift turnovers caused additional operational delays that impacted overall throughput efficiency.

Holcim Philippines partnered with Axians IAS to implement the comprehensive VAS yard management solution designed to automate and optimize their logistics operations. This end-to-end solution was built as a fully integrated smart infrastructure covering the entire truck handling process from entry to queuing to weighing, loading, and exit.

The VAS solution implemented timestamp tracking at critical process locations to collect time-based data for KPI generation and performance analysis, providing unprecedented visibility into operational efficiency. The system enabled truck drivers to complete more tasks independently through self-service terminals, significantly reducing the need for manual intervention by plant personnel and streamlining the overall weighing process.

A critical component of the solution involved upgrading the LAN backbone to enhance network speed, reliability, and overall system performance, addressing one of the fundamental challenges Holcim Philippines had faced. Axians IAS developed a scalable, hardware-independent system that integrated seamlessly with the existing IT infrastructure, including both SAP-connected and standalone (offline) operation options to ensure operational continuity under various conditions.

The smart infrastructure begins at the entrance, where drivers use a self-service gate-in kiosk equipped with an RFID reader, printer, and digital interface. When a truck arrives for a scheduled delivery, its RFID tag is automatically scanned, triggering the retrieval of relevant transport orders from the central system. For pickup operations, drivers perform self-service registration. A printed document (AW) is issued to the driver and simultaneously stored digitally. The entrance points can be equipped with barriers to control access flow and optimize yard capacity management.

To eliminate congestion and ensure efficient first-in, first-out (FIFO) handling, the yard employs a sophisticated queue management system. This includes paging systems and large-format queue displays that provide clear visual indications of truck status (such as “Next to Weigh In”). Driver lounge screens keep drivers informed in real-time about their position in the queue and estimated processing times, improving the overall driver experience while optimizing yard flow.

The weigh-in stations feature a comprehensive array of technology including RFID readers to verify truck and order data, traffic lights for lane management, cameras for documentation, and self-service terminals equipped with e-signature capabilities, printers, and digital displays. This technological integration ensures that all weighing data is captured accurately and transferred automatically to the central logistics system, establishing complete traceability throughout the process.

The final stage in the process occurs at the weigh-out station, which is structurally equipped similar to the weigh-in points with roofing, self-service kiosks, cameras, printers, RFID readers, and barriers. The system automatically compares the outbound weight with the inbound weight and calculates the final load. Drivers confirm shipment data through a digital signature and exit the yard without requiring any manual processing by staff members.

The VAS yard management solution was also implemented for Geocycle, Holcim’s global waste management company. This extension leveraged the same infrastructure and process flow, particularly for inbound operations, which are identical to the raw materials incoming goods process at the main plants. The implementation reduced manpower requirements through self-service capabilities for truck drivers. Geocycle leverages integrated planning through iDispo, enabling logistics staff to efficiently schedule and manage deliveries across operations. The system’s remote accessibility allows staff to monitor truck movements from any location, even outside the office, via VPN. Notably, the implementation included custom adaptations specific to Gecycle’s operations, such as moisture percentage tracking on the weigh slip and deductible calculations for pallets, addressing their unique process requirements.

The comprehensive hardware-agnostic system successfully integrates with existing silos, scales, and IT infrastructure while utilizing industrial-grade components throughout, including rugged industrial PCs, RFID systems, and printers designed to withstand harsh industrial environments. The scalable and modular architecture of VAS yard management supports future automation and can be readily retrofitted in other Holcim Philippines plants.