Case Study: Bayer Inc. achieves a paperless warehouse and major productivity gains with Tecsys WMS/400

Bayer - Customer Case Study

Bayer Inc. Canada, a $1.2B business that ships roughly 25,000 orders a month, faced rising complexity after consolidating multiple companies (1990–1994) and rapid healthcare growth. Their legacy batch systems and fragmented warehouse practices led to errors, slow inventory visibility and strained logistics staff, prompting a move to modernize operations and eliminate paper-based processes.

Bayer implemented TECSYS WMS/400 on its IBM AS/400 (customized for $250,000), deployed 46 Norand RF handhelds (including explosion‑proof units for a 46,000 sq ft HazMat centre), and restructured roles into a single multi‑level “warehouse operator” job. The paperless, wave‑picking operation with EDI carrier integration delivered measurable gains: on‑time implementation, higher accuracy and morale, real‑time inventory, ability to process about 1,200 orders/day (some in under 30 seconds), and a reduction in carriers from roughly 150 to about 15.

Bayer

Harold Mueller

Director of Logistics