The warehouse management system SAP LES/TRM is now controlling the existing central logistics centre of Bayer Schering Pharma in Leverkusen.

Balance sheet of the SAP integration are fully harmonised and transparent processes that are always flexible and they can be parametrised to growing and changing requirements.

As a member of Bayer AG, Bayer Technology Services GmbH (BTS) is a global provider of sustainable and market-based technology solutions for the chemical and pharmaceutical industry.

A first-class expert network develops, implements and optimises equipment, processes and products.
Thus, high quality and precise technology solutions arise, which go far beyond pure standard solutions and quickly pay-off for themselves.

Storage and transport systems for pharmaceutical unit goods are planned and implemented in the area of supply chain & logistics at BTS according to the latest state of the art and according to GMP / clean-room requirements.

Prior to the introduction, the challenge was a system to replace an external material flow system operating between an existing SAP LES system and the programmable logic controllers (PLC) at the technology level. At this point, of course, there had been considerations to supplement the existing SAP LES (logistics execution system) by an external subsystem for the material flow control.

Ultimately, however, there was consensus that no changes should be mad either at PLC or at SAP WMS level. The central objective was thus to reduce the complexity. But the issue of risk reduction also played an essential role. The greatest benefit therefore was to await an upgrade project on SAP R/3 ERP 2005 and replace the Old- or third-party system by the SAP TRM module - i.e. also to establish the material flow control integrated in SAP.

The simulation PLC-SAP developed by IGZ finds application. This should ensure maximum planning and thus also investment security at an early stage. Both SAP EWM/MFS as well as SAP LES/TRM alike can be used in this tool. All processes were depicted and physical movements of goods were simulated.

Based on the system model, the customising and development performances could be reviewed continuously for their functional correctness and if necessary adjusted. This proved very useful, even after commissioning: On the other hand, the simulation was helpful in the ongoing project. On the other hand, we also continue to use the model for simulation purposes. Bottleneck situations can be re-enacted before the physical intervention in the real system.

  • Carton conveyor
  • Conveyor scanner
  • High-speed scanner for "100% scanning"
  • Picking loops
  • 2 shipping sorters
  • MDE devices for loading/unloading
  • Document and label printer
  • Emulation tools for performance tests

  • Replacement of individual applications using SAP EWM standard processes
  • Optimal inventory and process transparency across all divisions
  • Avoidance of interfaces and related expenses.
Key Facts


  • Leverkusen


  • Data radio/MDE
  • Automatic inventory control
  • Batch tracing
  • Stacker control system

 SAP Product

  • SAP Console


  • Storage capacity: 32,000 pallet spaces, of which 27,000 in the automatic HBW
  • Manual warehouse, e.g. a small-parts warehouse, a chilled warehouse, a large container warehouse and an operating pallet warehouse
  • 2,600 Transport movements per day in a three-shift operation.