The Challenge
A tier-1 aerospace parts manufacturer was operating on an aging SAP ECC 6.0 environment. Their production planning (PP) and materials management (MM) processes were bogged down by slow batch processing, leading to inaccurate material requirements planning (MRP) runs. This often resulted in critical component shortages on the assembly line, causing massive production delays.
As they took on new, complex defense contracts, they required absolute precision and real-time visibility into their shop floor operations. They needed to upgrade to S/4HANA to leverage advanced MRP (MRP Live) and predictive analytics, but the migration required navigating millions of lines of highly customized ABAP code.
Architectural Solution
We executed a complex system conversion (Brownfield approach) to SAP S/4HANA. Using SAP Readiness Check and custom code analyzer tools, we meticulously refactored their legacy ABAP code to make it compatible with the new HANA database architecture, eliminating massive amounts of technical debt in the process.
Post-migration, we activated MRP Live, fundamentally changing how the manufacturer managed their inventory. Material requirements planning runs that previously took 8 hours overnight were now completing in under 15 minutes, allowing production planners to run simulations multiple times a day. We also integrated SAP Fiori apps on the shop floor, giving technicians real-time access to production orders and digital work instructions via tablets.
Business Impact
- MRP runs accelerated from 8 hours to 15 minutes
- Eliminated 65% of legacy custom ABAP code
- Reduced assembly line downtime by 28%
- Enabled real-time shop floor reporting via Fiori
Technologies Used
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