When Warehouse Workers Struggle With SAP EWM: How LeverX Turned Resistance Into Adoption

A logistics provider achieved full SAP EWM adoption with LeverX. Paper was eliminated in 4 months, picking accuracy rose by 30%, and cycle times improved by 20% through tailored change management.

Client

The client is a European logistics company specializing in warehouse operations and distribution services for retail and industrial customers. The company manages multiple warehouses and fulfillment sites across several European countries and supports high daily volumes of inbound, storage, and outbound movements, including goods picking and packing.

Challenge

The company had implemented SAP Extended Warehouse Management (EWM) with handheld scanners to improve efficiency, accuracy, and real-time visibility.

However, instead of a smooth adoption, the company faced resistance from its employees:

• Workers avoided using scanners and continued following paper-based processes.
• There were complaints that the system was too slow and required too many steps.
• Supervisors struggled with delayed, inaccurate data, undermining performance metrics.

This wasn’t a technical failure. The core system remained stable, but the workforce didn’t embrace new workflows.

If left unaddressed, the company risked facing the following issues:

• Lost ROI on its SAP investment
• Higher error rates and fulfillment delays
• A workforce disengaged from digital transformation

Solution

LeverX deployed a change management program designed for warehouse operations, focusing on the following areas:

1. Shop-floor engagement sessions

• Analyzed the daily pain points of the warehouse staff
• Identified specific frustrations with handheld workflows (e.g., too many fields, unclear navigation)
• Performed Organizational Change Management (training, communication, and user support) activities to facilitate the adoption of handheld workflows

2. UX and performance enhancements for SAP EWM Radio Frequency (RF)

• Reconfigured mobile workflows to simplify transactions, using clearer, more intuitive layouts that required fewer scans
• Prioritized execution speed, ensuring system performance matched the pace of operations

3. On-the-job simulations and coaching

• Conducted hands-on simulations during real picking and packing tasks
• Demonstrated how scanners can reduce errors compared to paper-based work
• Trained “peer champions” — experienced operators who mentored others

4. Continuous feedback and monitoring

• Created simple feedback loops so that workers could flag scanner issues daily
• Delivered adoption KPIs to the leadership (scanner vs. paper usage, error rates)

Technology Stack

The architecture for this project relies on SAP EWM and handheld RF execution for high-volume warehouse operations. We focused on combining back-end stability with the mobile flexibility required for workers on the shop floor.

• Core ERP/EWM integration layer: SAP Extended Warehouse Management (SAP EWM)

  SAP EWM serves as the primary intelligence to orchestrate the entire movement of goods, from inbound receiving to final dispatch, ensuring every pallet and bin is tracked with high accuracy.

• Mobile execution: SAP EWM RF Framework

  SAP EWM RF transactions on handheld devices help guide warehouse workers through daily tasks and capture confirmations in real time.

• Operational monitoring: SAP EWM Warehouse Management Monitor

  The module supports tracking execution metrics such as task completion, processing time, and adoption indicators across warehouse operations.

Results

Within four months, the LeverX team managed to achieve both technical precision and user empowerment for the client:

• Paper-based processes were eliminated, with all warehouse tasks running on SAP EWM RF workflows on handheld scanners.
• Picking accuracy increased by 30%, reducing costly rework and returns.
• Cycle times improved by 20%, directly impacting customer service levels.
• A complete shift in user sentiment was achieved, with workers championing the scanners as faster and more reliable than the old paper-based system.
• Leadership protected the ROI of SAP EWM, turning resistance into operational excellence.