In many manufacturing companies, inventory management and warehouse movements are still based on manual or paper-based processes. Despite having SAP, many organizations struggle because the standard SAP model is not fully optimized for the dynamic nature of on-site warehouse operations. The result is inventory discrepancies, wasted time, and frustration across warehouse, logistics, and production teams.
In a modern manufacturing environment, the goal is for every warehouse movement to be recorded in real time, with minimal effort and maximum accuracy. However, when warehouse operations are managed without specialized tools, multiple issues arise. Below, we identify the main challenges of managing warehouse movements using the traditional SAP and paper-based approach and then explore how a mobility-focused solution—such as SiMA—can transform these processes.
Issues with Manually Recording Warehouse Movements in SAP
- Errors from Manual Transcription: In manufacturing plants, it’s still common for operators to jot down material consumption for a production order on paper, which is later entered into SAP by someone else. A single miscopied digit in a material code—such as mistaking an MRO spare part for a critical raw material—can trigger a movement that directly impacts the consumption of a production order. These errors require manual corrections and may distort production cost calculations.
- Incorrectly Recorded Goods Movements: When material arrives at the warehouse but the movement is recorded hours later, the production line might start operating without SAP reflecting that availability. The same happens with unrecorded consumption, especially during shift changes. An operator might withdraw parts for maintenance without logging it immediately in SAP, creating a mismatch: the system shows available stock that is actually already in use or on an assembly line.
- Lack of Traceability and Evidence: If a pallet arrives damaged or a steel coil has a defect, in a manual environment there’s no evidence left in SAP. The movement may be recorded, but there’s no photo or validation of the item’s actual condition. In internal audits, inventory discrepancies are often found with no way to determine whether the damage occurred during receipt, in the staging area, or during transfer to production. It’s also impossible to know who physically handled the material if another user in the office entered the transaction.
- User Interface Not Suited for Shop Floor Operators: Transactions like MIGO or LT06 aren’t designed for someone wearing gloves or operating a forklift in front of a rack. Even SAP Fiori applications—while more modern—often replicate the same desktop-oriented screens and workflows, requiring excessive navigation and almost a mouse-level precision that’s impractical on the shop floor. In manufacturing, operators often need to scan a label or confirm a location transfer right on the production floor but end up writing it down on a paper for someone else to input into SAP later. This delay causes the movement to not be reflected in real time, leaving SAP stock data “frozen” compared to the physical reality.
- Disconnected Processes Between Logistics, Production, and Warehouse: Production may launch an order believing there are X units available in the warehouse, based on SAP, when they were already consumed by another line and the movement hasn’t yet been recorded. Logistics may plan a shipment unaware that the finished product is physically ready but hasn’t been posted. Each department maintains its own Excel sheets or physical logs, leading to redundant checks, phone calls, and manual verifications.
- Inability to Attach Supporting Documents (Photos, Signatures, etc.) in SAP: During the receipt of critical imported components or high-value parts, warehouse staff may take photos or request the carrier’s signature—but that evidence stays in a physical folder or someone’s personal phone. Linking it to the SAP movement requires additional transactions or external repositories, which are rarely used. As a result, in the event of a supplier claim or quality inspection, SAP lacks complete traceability for the movement.
As we can see, managing warehouse movements solely with standard SAP and traditional methods leads to errors, delays, and a lack of traceability. The good news is that there are specialized tools that enhance SAP MM, focusing on digitizing and streamlining each warehouse movement quickly and securely. Let’s explore how a mobility solution like SiMA addresses these challenges.
How a Tool Like SiMA Optimizes Warehouse Movements in SAP
To overcome the limitations mentioned above, companies are adopting solutions that complement SAP by fully digitizing warehouse operations. SiMA, developed by Innova, is an example of a specialized tool that radically improves how warehouse movements are recorded in SAP environments.
What functionalities does such a solution offer to optimize inbound and outbound flows? Below, we highlight the most important ones and how they contribute to a more efficient and connected warehouse:
Real-Time Recording from Mobile Devices
With an app like SiMA, operators can record each warehouse movement directly from a smartphone or tablet, right at the time and place it occurs. There’s no need to return to an office or wait until the end of the shift to enter data into SAP—the warehouse movement is posted instantly.
For example, when unloading raw materials from a truck, the warehouse worker opens the mobile app, selects the operation (e.g., goods receipt for a purchase order), scans or verifies the order number, and confirms the quantities received in seconds.
Immediately, the entry is reflected in SAP. By eliminating paper forms and delays, inventory information always remains up to date. This speeds up operations and reduces the administrative burden, allowing staff to focus on value-adding tasks rather than data transcription.
Barcode or QR Code Scanning for Increased Accuracy
A key feature is the integration of barcode/QR scanning into warehouse management. The app allows use of the device camera (or a Bluetooth scanner) to capture material, location, or SAP document identifiers.
This greatly accelerates data entry and eliminates manual input errors. Each time an operator needs to post a warehouse movement, they simply scan the corresponding code: material number, batch number, bin location, or even SAP document numbers (like a reservation or production order). For instance, in an outbound movement to production, the operator can scan the production order barcode and then the material labels; the app will automatically populate the transaction.
This automation ensures the correct item is moved in the correct quantity, preventing confusion from similar numbers or illegible handwriting. It also speeds up the process—registering a full pallet is as fast as scanning a label, instead of typing dozens of positions manually.
User Interface Designed for Warehouse Operators (Simple and Usable)
Unlike SAP’s generic transactions, solutions like SiMA offer a clean user interface tailored to warehouse tasks. This means touch-optimized screens built for warehouse staff. Buttons are large, options are presented in a clear step-by-step flow (e.g., first select movement type, then scan or enter the identifier, then confirm quantity), and only the necessary information is shown for that specific operation.
This simplicity greatly improves the user experience. An operator can learn to use the app in a short time, with no need for deep SAP knowledge. Plus, the interface is designed with real working conditions in mind: warehouse lighting, glove use, intermittent connectivity, etc. The guiding principle is simple—the more intuitive the app, the more consistent and complete each warehouse movement record will be in the system.
Attachments and Additional Data (Photos, Signatures, Geolocation)
A major improvement SiMA brings is the ability to attach contextual information to each warehouse movement. From the same registration screen, the operator can take photos (e.g., of damaged materials or a security seal on a shipment), capture the carrier’s or receiver’s digital signature, and even record the geolocation of where the transaction occurred. All of this is automatically linked to the material document in SAP.
Thus, every movement is backed by digital evidence that would otherwise be lost: if a batch of defective material is received, photos are tied to the goods receipt; if materials are delivered to production, the area supervisor can sign digitally on the spot. This feature takes traceability to a new level, making the process fully digital and paperless.
During any audit or later analysis, users can review the warehouse movement in SAP and find not only numbers, but also visual proof and confirmations of who performed each step, when, and under what conditions.
Autonomous Correction of Erroneous Movements
Mistakes happen, but with the right tool, correcting a warehouse movement can also be done by the operator in seconds. SiMA includes options to reverse or adjust material documents directly from the mobile device, always respecting SAP authorizations.
Consider a common scenario: during an outbound movement, 100 pieces were entered by mistake instead of 10. In standard SAP, the operator would need to inform a supervisor or go to a terminal with SAP GUI to reverse the movement and re-enter it correctly—wasting time and leaving incorrect inventory data in the meantime.
With a mobile solution, the same warehouse worker identifies the error on the spot and can reverse or correct it directly in the app: they cancel the incorrect document and enter the correct quantity. The process is guided and validated to meet SAP rules, but only takes a few taps on the screen.
Giving this autonomy to warehouse staff avoids bottlenecks and ensures inventory data remains accurate—even when a mistake occurs. Daily operations become more agile, and operators take direct ownership of their entries, closing the loop for each warehouse movement without relying on others.
Full Traceability and Real-Time Data
All of the above functionalities converge in the most valuable benefit: end-to-end, real-time traceability. Every time a movement is registered with SiMA, the information is instantly updated in SAP and made available to all relevant departments. Logistics, planning, procurement, and production are all seeing the same data at the same time—no gaps. Additionally, the system logs exactly who performed each movement, at what time, in what location, and with what supporting documentation.
This real-time traceability allows, for example, a production planner to confirm on their screen that a specific raw material was delivered to the manufacturing area 2 minutes ago—with a photo included—instead of calling the warehouse.
Or for the quality department to trace who received a defective batch and view the damage photos attached to the movement. Integration eliminates disconnected processes: the warehouse no longer operates in a silo—its stock movements feed directly into the ERP and decision-making process.
Ultimately, the company achieves an intelligent warehouse, where every movement is efficient, documented instantly, and immediately reflected in the digital supply chain.
