At the beginning of the year, one of our clients faced a situation no supply chain leader ever wants to experience.
Several disruptions hit at the same time:
• A sudden OEM portfolio mix change created planning instability
• A non-functional SAP implementation caused incorrect and missing system data
• A cyberattack at a Tier1 supplier further disrupted information flows
The result?
Production and delivery planning collapsed.
No reliable order intake status.
Incorrect data in the system.
No functioning EDI automation.
Wrong ASNs.
And dispatch operations running almost completely manually.
Shipments were delayed, trucks were waiting for hours, and communication between stakeholders was breaking down.
This is where KCG stepped in.
Stabilizing the Situation — Fast
Instead of waiting for systems to be fixed, we focused on operational control first.
Within hours, we deployed a 24/7 on-site dispatch control team, working seven days a week to regain visibility and structure in the shipping process.
Our approach included:
✔ Building a complete dispatch control structure from scratch
✔ Implementing transparent reporting every 2 hours on truck status
✔ Introducing daily KPI reporting to track operational performance
✔ Establishing clear escalation and communication channels internally and externally
✔ Physically monitoring loading processes and truck departures on the shop floor
Because system visibility was unreliable, we added an additional layer of control:
• Direct hourly communication with drivers
• Parallel GPS tracking implementation
• Physical verification of shipments leaving the plant
This combination of digital tracking, operational presence, and constant communication allowed us to regain control over the logistics flow.
The Impact
Within a very short time, the operation stabilized and performance improved significantly:
📦 Full control and monitoring of all shipments within 24 hours
📦 More than 75 additional shipments per week handled after project launch
📉 50% reduction in special freight costs within just 1.5 months
⏱ Truck waiting times reduced from over 6 hours to less than 2 hours
📊 Shipment tracking KPI system implemented
🚛 Dispatch capacity increased by opening an additional loading gate
📍 GPS tracking system introduced, reaching ~80% readiness despite equipment limitations
What This Case Shows
When supply chains face multiple simultaneous disruptions, the solution is rarely just technology.
What makes the difference is:
• Operational leadership on site
• Real-time transparency
• Structured escalation processes
• Disciplined execution at every step of the dispatch process
Sometimes, the fastest way to stabilize a system is to take control of the operation itself.
If your organization is dealing with dispatch instability, missing transparency, or logistics crises, we would be happy to exchange experiences.