Sumitomo (SHI) Demag: seamless transformation instead of a hard cut
Success Story Many companies in mechanical engineering face a crucial question: how can the specific...
Contents
Many companies in mechanical engineering face a decisive question: how can the specific requirements of engineering and production be separated sustainably, without giving up the advantages of historically grown structures? While many organisations are still grappling with this challenge, Sumitomo (SHI) Demag has taken an innovative and practical path together with BDF EXPERTS, and has set the course towards the future in doing so.
The starting point: two worlds, one goal
In the engineering of injection moulding machines, two fundamentally different perspectives meet: the function-oriented design world of engineering and the assembly-focused production viewpoint. This “forced symbiosis” led to considerable challenges at Sumitomo (SHI) Demag:
- Mixed structures: engineering documents and production requirements competed in the same systems
- Complex migration: a radical system change would have jeopardised proven processes and risked data loss
The objective was clear: better scalability, a clear separation of responsibilities and more effective workflows, without the abrupt loss of established processes.
Why standard SAP processes are no longer enough
Whether order-related, project-based or completely free deliveries, the requirements are as varied as your customers. In the whitepaper, find out where classic SAP ERP processes reach their limits and what modern alternatives are available.
The solution: SAP PPG with an innovative production resource structure
The key to a successful transformation lay in a tailored solution based on SAP Product and Process Governance (PPG), developed by BDF EXPERTS.
The PRS approach:
- Production Resource Structure (PRS): This innovative structure separates production-related priorities from engineering requirements. From the Engineering Bill of Materials (EBOM), a rule-based transformation creates a production-order-specific structure (POS). The basis of this structure, together with all manufacturing requirements such as the routing and so on, is the PRS.
- Coexistence instead of a hard cut-over: Unlike classic migrations, the approach does without an abrupt switch. The old world, such as classic EBOM bills of materials, is retained and used in parallel with the new structures. This is how the step-by-step transformation succeeds without disruption.
Technical details and special features
- The EBOM is retained as a material bill of materials and can continue to be used.
- PRS and POS enable a clear separation and targeted reuse of production-relevant information
- Departments can rely on established or new workflows and at the same time benefit from a transparent data structure and traceable documentation of every component.
The key benefits
- Clarity and focus: Engineering and production can concentrate on their own core competencies and workflows.
- Sustainability and flexibility: the solution can be extended at any time through rule-based transformation, while also supporting proven processes.
- Transparency and traceability: every processing step and every part delivered is traceable, whether CTO, CTO+ or ETO components.
- Strategic support: The implementation contributes directly to the corporate strategy: a clearer separation of processes, greater scalability and the opportunity for continuous optimisation.
What makes this project unique
The solution implemented with SAP PPG and PRS enables a rule-based merger of the proven and the innovative. Established engineering structures are preserved without compromising on future viability. Novel structural concepts such as the Production Order Structure (POS) deliver greater consistency, traceability and efficiency, a model step for the entire industry. Further process optimisations were already identified during the project, and their implementation is planned for the coming phases. The prerequisite: the flexible PRS architecture can be adapted at any time without disruption.
Outlook: ready for scaling, optimisation and innovation
While most organisations still have to mediate between engineering pragmatism and production reality, Sumitomo (SHI) Demag, with the support of BDF EXPERTS, has created a future-proof solution and laid the foundation for continuous further development.
About Sumitomo
Sumitomo (SHI) Demag Plastics Machinery GmbH is an international manufacturer of injection moulding machines and systems, headquartered in Schwaig near Nuremberg with a second German plant in Wiehe (Thuringia).
Since 2008, the company has been part of the Japanese Sumitomo Group and combines German and Japanese engineering to deliver precisely tailored production solutions for plastics processors worldwide.
A strategic focus lies on expanding all-electric platforms (including IntElect) as well as on integrated system solutions, automation concepts and digital services that support efficiency, energy savings and process stability in manufacturing.
About BDF EXPERTS
BDF EXPERTS is the brand of bdf consultants GmbH, a leading SAP Silver / SolEx partner with comprehensive end-to-end expertise in Digital Supply Chain and Corporate Finance & Treasury (CFT).
For more than 25 years, BDF EXPERTS has been helping companies, on the basis of SAP ERP and S/4HANA, to achieve measurable value creation through fully digitalised processes. In Digital Supply Chain, BDF EXPERTS has developed particular expertise in holistic data management.
With SAP PPG (Product and Process Governance), BDF EXPERTS offers an innovative solution for centrally managing all product and process data in SAP, thereby laying the foundation for data-driven business models.
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Would you like to learn more about implementing SAP PPG in your company? Our experts will be happy to advise you individually.
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The BDF EXPERTS Insights platform is aimed at decision-makers and specialists working with SAP, supply chain and corporate finance. It offers well-founded expert articles, practical insights and strategic perspectives on process harmonisation, digitalisation and technological developments.
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