Rewiring operations: the shift from reactive to real-time in finished vehicle logistics
With disruption now the norm across automotive supply chains, reactive operations are no longer viable. The next phase of operational excellence will be defined by real-time visibility – combining data, processes and people to enable faster, smarter decisions across the network.
The finished vehicle logistics industry is no stranger to pressure, but this decade has seen a number of disruptions that have exposed structural weaknesses. Capacity constraints, labour shortages, volatile production schedules and rising costs have continued to challenge the sector’s ability to deliver vehicles efficiently and on time.
Against this backdrop, the industry is being forced to modernise operations that have historically lagged behind upstream supply chain in terms of digitalisation.
The urgency with which finished vehicle logistics operations must modernise was reflected on stage at Automotive Logistics' recent Finished Vehicle Logistics conference in California, where industry leaders repeatedly highlighted the limitations of traditional, reactive models.
Real-time visibility
To truly move away from a reactive model towards more dynamic operations, real-time visibility is essential. There are so many different handoffs within finished vehicle logistics – across plant yards, rail stations, ports, vessels, compounds and dealerships – that can cause fragmentation in the network, so having a end-to-end view in real time ensures any issues can be addressed before they disrupt operations.
"The supply chain is very complex – there are lots of touches on a vehicle from plant release to delivery to the final destination," stated Nathan Lawson, vice president of customer success at Overhaul. "So what we focused on is how to get a more proactive, real-time view of when damage takes place."
He explained that this level of visibility not allows Overhaul to address issues immediately rather than waiting until a claim is made by the dealership, but also allows the company to make setbacks visible to the whole ecosystem. Every stakeholder in the finished vehicle supply chain is aiming to eliminate damages, so end-to-end transparency can allow everyone involved to support in the achievement of this shared goal.
Technology for visibility
To improve visibility, certain technologies are needed to ensure the right data is being collected. The need for real-time insights has driven investment in technologies such as: connected vehicle data to monitor battery health, location and status; sensors and telematics to detect shocks and risks; and AI-enabled imaging systems to provide consistent inspection data across touchpoints.
Yaron Saghiv, chief marketing officer at UVeye, explained how the company has built a machine, which he described as "like an MRI for cars" – using AI, these machines scan the whole car to check for signs of damage (dents, scratches, roof leaks, broken parts, missing parts etc).
"These machines are installed across retailers, plants, rental companies – all across the lifecycle – and we have over 1,000 machines today," Saghiv said. "So if we work with an OEM, we're able to analyses and assess the damage and liability, but also the data."
He continued: "Once you have big data from consistent inspections, which frankly we think we have proved could be done much better by a machine than a person – specifically the inspection process – we're able to analyse and give really smart insights with that data, so it's all about consistency for us."
BMW's data-driven approach to yard management
At BMW Group’s plant in San Luis Potosí, Mexico, yard management is becoming a critical control point in the shift towards more connected, data-driven vehicle logistics operations.
Speaking at FVL NA 2026, Jochen Schneider, manager of production control and vehicle distribution at BMW Group Plant San Luis Potosí, highlighted that the primary challenge is no longer a lack of information, but how effectively it is structured and connected. The focus, he explained, is on ensuring the “availability of data and the useful connection of all the data so that it speaks to you,” enabling a true 360-degree view of outbound operations.
Within the yard environment, this means moving beyond static tracking towards real-time awareness of vehicle status, location and movement. By linking data across production, yard handling and outbound logistics, the plant is working to create greater transparency at each step in the process.
A key priority is developing real-time cost awareness alongside operational visibility – understanding not just where vehicles are, but the financial impact of each movement and delay. This allows teams to make faster, more informed decisions and respond dynamically to changing conditions.
Ultimately, the approach reflects a broader industry shift: transforming the yard from a passive storage space into an active, data-led hub that supports end-to-end visibility and operational control.
People and processes
Despite the emphasis on digital tools, speakers repeatedly cautioned that operational excellence is not purely a technology problem, and technology alone is not enough to make this transformation successful.
Speakers emphasised the need for the right processes and skilled individuals to ensure consistent execution, with these inconsistencies, rather than a lack of available technology, proving to be the root cause of quality issues.
"Consistency is very, very important for us, and it's about building that culture of quality and demanding high standards of individuals," said Scott Goodwin vice president of OEM Services at KhS Global.
The future of vehicle logistics operations
Looking ahead, the evolution of operations in finished vehicle logistics will be defined by how effectively organisations integrate data, technology and processes into a unified model. As speakers at the event in California highlighted, the transformation towards an open, connected ecosystem where data flows seamlessly between stakeholders is still in its early stages, but momentum is building.
By combining AI-enabled predictive insights, quality data and a skilled workforce, the industry can transition from fragmented, reactive operations towards a synchronised, real-time network that can respond instantly to disruption and continuously improve performance.
