Plan, control and optimize

As a result of a successful project collaboration, the non-ferrous metal processor now maps all production processes at the Meinerzhagen site across all manufacturing stages in SAP ERP/ECC 6.0, without any media breaks from the receipt of components to the delivery of the finished product. Founded in 1910, the company is a leading international supplier in the non-ferrous metal industry.

The business relationships are global, with customers particularly in the aerospace, automotive and construction industries, as well as in industrial engineering. The demand for lightweight components for electric vehicles is growing. "However, the production of assemblies in the field of e-mobility places diverse demands on our IT systems", explains Udo Keller, Global Head of IT at Otto Fuchs. "With the processes now available, we see ourselves well equipped for the future."

With the increasing networking of machines and IT systems, however, development is taking on a new quality. It won't work without store floor functions and without a central control element and link. The individual modules for planning, controlling and optimizing complex production environments are outside of SAP ECC 6.0, but are consistently aligned with SAP from the start.

The assembly that Otto Fuchs produces on the new production line at the site in Meinerzhagen consists of several serialized and batch-managed components. Mapping this complexity from several logical levels in the IT was the challenging task of the SAP consulting partner. Together with internal IT, the requirements of all departments involved were recorded. A feasibility analysis followed as part of the process consulting, before a rough and detailed concept were created.

Since the necessary infrastructure with SAP standard objects, plant data collection and mobile applications was already in place, an initial prototype could be created quickly. The project partners reached their goal via individual programming to extend the standard. "The project went just great", reports Volker Schröders, Head of IT-ERP at Otto Fuchs. "The boundary conditions were challenging. All the nicer that we were able to implement the project so smoothly and successfully."

All processes associated with manufacturing - from goods receipt of the components to goods issue of the finished product - are mapped in ECC 6.0 without media breaks. The focus of the process design is on traceability down to the lowest component level as well as scalability in terms of the number of assemblies or assembly stages. The solution can easily be rolled out to other plants. In addition, the new system offers the best prerequisites for the planned migration to S/4.

The solution enables Otto Fuchs to monitor and control production holistically in real time. This includes, for example, plausibility checks of the components and auxiliary materials used. Last but not least, the creation of the required documents from one system, such as the acceptance test certificate, is a decisive aspect. (pmf)