Industry: Automotive supply industry (discrete industry)
Role: Senior Expert Consultant / Production & Logistics [Stream Lead across all sub-streams]
Focus: SAP SD, PP, MM, WM, PM, shop floor/MES integration, planning, aftermarket

ElringKlinger AG is a leading international automotive supplier headquartered in Dettingen/Erms (Germany). The company develops and manufactures sealing systems, plastic modules, shielding components, battery systems and fuel cell technologies for virtually all global vehicle manufacturers. In addition to traditional series production, the growing e-mobility sector is one of its strategic areas for the future.

The aim was to optimise and harmonise SAP-based production processes across several European locations. The focus was on integrating manufacturing, logistics and quality assurance into a consistent SAP process model and preparing for an international rollout.

Scope of services & tasks

 

Management, coordination and responsibility for stream operations and its sub-streams

  • SAP SD, PP, MM, WM, PM, Integration Shopfloor / MES, Planning, Aftermarket,
  • Definition of target processes for production planning, material provision and production control.
  • Integration of adjacent modules: Interfaces to QM, WM, SD and CO to create a consistent process landscape.
  • Add-on specifications: Development of customised extensions for fine-tuning production orders and logistics bookings.
  • Introduction of mobile data capture (MDE/BDE): Integration of scanners, terminals and production workstations for real-time feedback in the SAP system.
  • Customising & test management: implementation, integration testing and training of key users.
    • Function descriptions and migration concepts, creation
    • Management of the design and build phase – definition of test cases and their implementation for
    • integration tests
    • Implementation of UAT, cut-over and go-live
    • Definition and control of test activities, including logging/processing of
    • Bugs together with the customer and sub-stream lead, as well as in our own sub-stream manufacturing
    • Support for end-to-end integration testing: Practical contribution to ensuring
    • Completeness and quality of the e2e integration test process and independent tests – performing validation during data migration

Challenges

  • Heterogeneous system landscape due to different plants and countries
  • Mapping complex manufacturing processes
  • Lack of transparency in material flows and feedback
  • Need for standardised, scalable processes to prepare for global rollout
  • SAP Best Practice mit FIORI Integration vs. SAP GUI
  • Highly customised developments

Solution

  • Development of a cross-location SAP template to standardise production and logistics processes
  • Integration of mobile data capture systems (Mobisys Add-On) for real-time manufacturing and logistics bookings
  • Close integration of quality management and production control (QM-PP)

Results & Benefits

  • Standardised manufacturing processes and improved planning quality
  • Improved data quality and transparency through centralised process control
  • Significant reduction in manual entries and process errors
  • Optimised throughput times through improved production control
  • Contribution to the digital transformation of manufacturing in the context of Industry 4.0