In 2025, U.S. manufacturers are entering a new phase of supply chain strain. Tariff uncertainty, escalating transportation costs, and mounting delivery risks are prompting companies to stockpile raw materials and components at levels not seen in more than two years. The outcome is clear: warehouses, docks, and yards are reaching their breaking point.
While front-loading inventory can help hedge against cost volatility, it also creates operational friction. Surges in inbound freight, congested docks, extended dwell times, and unpredictable scheduling challenges can erode margins and damage reputations. But manufacturers that partner the stockpiling strategy with operational intelligence, especially via modern yard management and dock scheduling tools, are poised to emerge as shippers of choice.
This article explores the stockpiling trend, why “smart yards” matter, and how deploying the right systems and practices can transform risk into competitive advantage.
Tariff volatility and cost anticipation are the main triggers. As trade policies shift, manufacturers are preemptively purchasing goods to avoid upcoming duties or cost spikes. For example, Deposco reports a 228% increase in Days of Inventory on Hand (DIOH) between February and April 2025 among U.S. companies responding to tariff threats.
Delivery risk and lead-time uncertainty are also playing a growing role. According to surveys, U.S. manufacturing saw supplier delivery times reach their longest levels in nearly three years, driven by tariffs and growing supply disruptions. These longer delivery windows force manufacturers to hold more inventory than they otherwise would.
The shift from just-in-time (JIT) to just-in-case (JIC) is reshaping supply chains. Manufacturers once leaned heavily on lean inventory and JIT models but are now adding buffers to cushion against cost and lead-time shocks. Customs complexity and dock delays are reshaping supply chain economics—making scheduling efficiency a business-critical priority.
Finally, stockpiling creates mounting pressure on warehouse networks. As companies bring in larger volumes of goods ahead of tariff changes, available capacity tightens, and the costs of holding inventory—including storage, insurance, and financing—continue to rise. Inbound surges are leaving goods idle for longer, driving up carrying expenses and straining distribution facilities.
Stockpiling doesn’t just impact financial statements. The operational burden shows up in yards, docks, and scheduling.
Dock congestion and scheduling bottlenecks are common as more raw material shipments arrive earlier or in bulk. Without effective dock scheduling software, appointments overlap, deliveries queue, and wait times increase.
Yard dwell time and detention costs also rise. Trailers waiting too long in yards consume space and labor. Unloaded or loaded trailers that sit idle incur detention fees and hamper yard flow. Unplanned dwell times can add $50 to $100 per load in extra cost.
Labor inefficiency is another hidden cost. Without visibility into what’s in the yard, where trailers are parked, or which trailers are ready to move, staff spend time searching instead of executing. Manual check-ins and a lack of trailer tracking waste labor and slow cycle time.
All of this creates operational risk and reputation damage. Delays, unpredictability, and overruns on appointments harm relationships with carriers and downstream partners. In times of capacity constraint, reliability becomes a key differentiator for manufacturers seeking to be the partner of choice.
A smart yard is not just bigger; it’s more intelligent. Modern Yard Management Systems (YMS) bring the following capabilities:
Real-time visibility of trailers, assets, and door status. Knowing where trailers are, whether full or empty, and which dock doors are occupied allows faster decision-making.
Automated dock scheduling and appointment management: Carriers can book ahead, get notified of available windows, and avoid overlaps. Exceptions and reschedules are managed dynamically.
Task and trailer movement optimization: Assigning moves to yard jockeys or spotters based on real-time data ensures assets are in the right place at the right time, reducing idle time.
Integrated systems across YMS, WMS, TMS, and ERP. When yard, warehouse, transportation, and enterprise systems are siloed, miscommunication and misalignment are inevitable. Integration ensures changes ripple through the supply chain in real time.
Data analytics and predictive planning: Using historical data and what-if modeling helps anticipate shipment surges, adjust staffing, forecast storage needs, and avoid bottlenecks before they happen.
According to Logistics Management, 2025 updates in yard management systems are enabling “more connected, responsive yard environments that keep freight moving, reduce dwell time, and support broader supply chain flow.”
What does it mean to be a shipper of choice in an environment where inventory pressures and capacity constraints are real?
Reliability under pressure is the first factor. Carriers and suppliers prefer working with manufacturers who adhere to appointments, minimize wait times, and maintain predictable throughput. Manufacturers with smart yards reduce dwell and improve turnaround, which builds trust.
Lower costs and more efficiency are equally important. Reduced detention fees, lower labor overtime, and less idle asset cost all help offset the additional burdens that stockpiling creates.
Flexibility and responsiveness matter too. If demand or trade policies shift suddenly, manufacturers with modern yards can adjust quicker: reschedule inbound volumes, reroute shipments, and scale operations up or down.
Finally, better supplier and carrier relationships emerge. Carriers prefer shippers who make their lives easier with shorter wait times, clear instructions, and predictable flow. These shippers often get preferential treatment: access to better lanes, more favorable rates, and more reliable capacity when markets are tight.
To move from merely coping with stockpiles to leveraging them as a competitive advantage, manufacturers must treat yards and docks as strategic assets. This requires structured audits, advanced metrics, and system orchestration.
1. Audit Yard and Dock Operations with Data-Driven Mapping
Go beyond visual inspections—capture gate entry timestamps, trailer dwell locations, and actual vs. planned dock assignments. Use digital twin mapping or time-motion studies to uncover systemic bottlenecks such as high congestion zones, unbalanced dock utilization, or excessive gate processing times.
2. Measure and Benchmark Key Yard KPIs
Track dwell time (arrival to dock door), trailer turn time (dock to departure), door utilization percentage, detention/demurrage fees, and driver wait times. Compare against industry benchmarks from sources such as the American Transportation Research Institute or CSCMP’s State of Logistics. These KPIs highlight cost leakage and opportunities for process automation.
3. Deploy Advanced Dock Scheduling Capabilities
Move from static appointment books to dynamic dock scheduling platforms that support exception handling, automated reschedules, and predictive slot allocation. Look for systems that incorporate live ETA feeds, driver check-ins, and API connectivity to TMS/WMS, enabling proactive adjustments when inbound surges occur.
4. Adopt an Integrated Yard Management System (YMS)
A modern YMS should provide real-time trailer visibility (via IoT sensors or GPS), integration with WMS/TMS/ERP, and task automation for yard jockeys. Advanced systems include predictive analytics, allowing planners to simulate the impact of stockpiling surges on yard throughput. Prioritize platforms with mobile interfaces for gate staff and carriers to reduce manual paperwork and latency.
5. Automate Carrier Communication and Gate Processes
Replace phone/email coordination with digital appointment confirmations, geo-fenced driver notifications, and automated gate kiosks. Automating check-ins reduces average gate processing times by several minutes per truck, freeing up yard capacity while improving the driver experience—a key factor in being viewed as a “shipper of choice.”
6. Build Scenario Planning into Scheduling Models
Use historical shipment data, tariff policy changes, and demand forecasts to model multiple inbound surge scenarios. For example, simulate a 30% increase in container arrivals within a two-week period and test whether current yard staffing and dock slot allocation can handle the load. These exercises help pre-position staff, assign overflow yard space, and align contracts with carriers.
7. Engineer Yard Layout and Optimize Asset Deployment
Apply lean engineering to yard design: segment space into inbound, outbound, and staging zones; position high-turn trailers closest to docks; and use algorithms to minimize deadhead travel for yard trucks. Incorporate yard automation (sensors, RFID gates, drone scans) to track trailer positions in real time, eliminating wasted search time and idle moves.
See how all these capabilities come together in one platform that unifies scheduling, visibility, and freight flow. Book a 20 min demo here today.
Stockpiling raw materials and parts has become one of the strategic responses U.S. manufacturers are using to hedge against trade policy risk, rising costs, and supply chain disruption. Yet, this strategy brings its own strain—on warehouses, docks, and yards.
Smart yards are the differentiator. Manufacturers that invest in visibility, automation, scheduling precision, and integrated systems won’t just endure the operational turbulence; they’ll thrive in it. They’ll earn reliability, reduce friction, and position themselves as shippers of choice in a tight capacity market.
In late 2025 and beyond, the most successful manufacturers won’t just be the ones with the deepest inventory; they’ll be the ones with the smartest yards. By investing in visibility, automation, and scheduling precision, they’ll transform risk into resilience and stand out as true shippers of choice