Project Summary

Organization

Steel rolling mil
manufacturing

Scope

Implementation of
SAP/HANA

Type of Work

• Implementation
• Integration with 3rd party
• systems like weigh bridge

Environment

SAP / S4 HANA

Modules

• Financial Accounting (FI)
• Controlling (CO)
• Plant Maintenance (PM)
• Quality Management (QM)
• Production Planning (PP)
• Materials Management (MM)

The client is a re-rolling mill with a production capacity of 400 kilograms per day, today client has a production capacity of over 1.5 million tonnes annually, being produced at multi-locational, state-of-the-art plants. It stands tall as one of the most trusted and reputed brands for high strength steel bars in the secondary steel sector of India

The Solution

Planning and Preparation

• Conducted a thorough analysis of existing processes, identifying pain points and areas for improvement.
• Developed a comprehensive project plan, outlining timelines, milestones, and resource requirements.

System Design and Configuration

• Collaborated with our SAP experts and consultants to design a tailored solution based on SAP S/4HANA.
• Configured the system to align with client’s unique business requirements, ensuring seamless integration with existing systems.

Data Migration and Testing

• Migrated historical data from legacy systems to SAP S/4HANA, ensuring data accuracy and integrity.
• Conducted extensive testing to identify and resolve any issues related to data migration, system integration, and overall functionality.

Training and Change Management

• Implemented a comprehensive training program to familiarize employees with the new system.
• Established change management processes to address resistance and facilitate a smooth transition to the new ERP system.

Go-Live and Optimization

• Launched SAP S/4HANA across all departments, closely monitoring system performance and user feedback.
• Continuously optimized the system based on user feedback and evolving business needs.

Key Focus

• Increased production output
• Increased control on quality
• Optimal machine uptime
• Optimal Downtime
• Increased Yield
• Increased Sales revenue

The following performance indicators (KPIs) for the client organization were achieved:

Production Output” Tracking and Monitoring the production output involves determining the cumulative quantity of rolled products manufactured during specific time intervals, such as daily, weekly, or monthly periods

Quality Control:The QM module assesses the proportion of rolled products that adhere to the quality standards established by the company, encompassing criteria such as dimensional accuracy, surface finish, and material properties

Machine uptime:The solution helps in measuring the amount of time the rolling mill machinery is operational, and can help identify potential bottlenecks or inefficiencies
Yield:Client organization was able to measure the percentage of raw materials that are converted into finished rolled products, and can help identify areas for improvement in the production process

Downtime:Tracking and Monitoring of the amount of time that the rolling mill machinery is not operational, and can help identify areas for improvement in maintenance and repair processes