Optimization of production planning for uvex plant in Fürth

Transcription

1 CAMELOT ITLAB Customer success story _Technologies _Products & Solutions _SAP Applications Optimization of production planning for uvex plant in Fürth uvex saftey group, SBU Eyewear successfully implemented SAP ERP PP & SAP APO PP/DS The uvex safety group is the market leader for products and services for safety and protection of people in the areas of sports, leisure and work. In the area of eye protection the uvex safety group with the production plant in Fürth was faced with the challenge to increase the efficiency and transparency of the existing production planning processes and to put them on a modern information technology. Statement With this project uvex has achieved a modernization of its process- and IT infrastructure. Not only a change in production planning but also the integration of production planning to all SAP modules have been achieved with the successful implementation of SAP ERP PP and SAP APO PP/DS. This was a necessary and important step for uvex towards a future-oriented system landscape. Joachim Ott Head of Group Information Management, uvex Winter Holding From Innovations to Solutions.

2 CAMELOT ITLAB Customer success story Optimization of production planning Successful implementation of SAP ERP PP & SAP APO PP/DS Figure 1: v.l.t.r. Mr. Schumacher (Project leader), Mr. Götzelmann (Head of Quality Management SBU Eyewear and Head Protection), Mr. Kalb (Managing Director USL), Mr. Decker (Leiter SCM SBU Eyewear & Head), Mr. Bachmann (Head of KIM Organisation), Mr. Wirth (Head of Production Planning Eyewear), Mr. Pascher (Head of Controlling Information Management uvex safety), Mr. Stockmeyer (Master Data Manager TK Safety), Mr. Ott (Head of Group Information Management) uvex Winter Holding), Mr. Wolf (Partner Camelot Group), Mr. Dr. Schäfer (Head of SBU Eyewear & Head) Challenges Decision Increasing demand to improve the profitability of business activities (value focused, asset management) Higher complexity of planning and scheduling processes (i.e. deepening of division of labor and faster realization of product innovations) Development of a graphical tool for production planner Modelling established master data structures from existing system (AS / 400) in SAP Integration in logistic processes (material management, warehousing, quality management, sales and distribution) The implementation of SAP ERP PP and SAP APO PP/DS and changes to the product planning processes were to overcome the challenges. Only Camelot ITLab could guarantee the dual approach as implementation partner: Process- and application know-how combined with expert knowledge in the area of supply chain management. Statement The basis for the project success was certainly the project team and the full support from management during all project phases. The cooperation of representatives from planning, production, procurement, controlling, IT and consulting partner have been close and constructive. The comprehensive process understanding, the extensive project experience in combination with the profound SAP know-how of the Camelot consultants ensured high project quality during every project phase and prevented unpleasant delays. Klaus Schumacher Project lead, uvex saftey group, SBU Eyewear

3 Project preparation 1 2 Blueprint Project preparation Design & blueprint Preparation Project kick-off Rough concept Functional concept serves as basis for IT concept, assessment and implementation IT concept describes technical realization Processes & organization Standardization of master data Quality management System architecture, basis and development Project management & methods Authorization concept Project preparation Team mobilization Project planning System architecture Workspace Onboarding As-Is analysis Objectives (measurable, incl. criteria) Requirements (specified) Functional concept Business processes user model Authorization concept Data model Function model Interfaces / Integration Cross requirements and concepts (functional) Test specification User documentation Operations (infrastructure & architecture) Project management (update) IT concept Change management / training SAP ERP / APO overview training SAP ERP / APO advanced training Development & coordination of training concept Project objectives Project scope Improvement of customer satisfaction (service excellence, faster and more reliable confirmation and keeping of delivery dates, reduction of delivery times) Securing growth targets and market leadership of uvex (opening up new markets, increasing production volumes, more orders, smaller lot sizes) Improved transparency of planning and scheduling processes in manufacturing Camelot was assigned to the demanding project and realized the project within 12 months: Optimization of production planning and scheduling processes Replacement of production planning and scheduling (PPS) in previous AS/400 system Implementation of production planning processes for plant Fürth in SAP ERP PP and APO PP/DS Integration to material management, procurement, warehousing (SAP modules MM and WM), quality management (QSYS), sales (SAP module SD) and finance and controlling (SAP module FI/CO)

4 Realization Final preparation Go-Live support Run SAP Implementation Go Live Coaching Run Delivery of functional concept and IT concept with gradual integration to sub systems, The solution goes productive: Go-Live, transition to operation and project closure Configuration Customizing Additional developments Training Development of training material Training of users Testing Functional tests Test development (general) Integration tests User tests User documentation Project management Go-Live Test run Start production Issue solving Open points incl. need for stabilization Coaching of users Training documents Training / coaching The Camelot project approach: To guarantee the project success the experienced Camelot project team applied their proven 4-phase project approach: Phase 1: Project preparation & Kick-Off In this phase the team mobilization, detailed project planning, As-Is analysis and description of project goals based on the project plan have been conducted. Phase 2: Design, Blueprint & Prototyping This phase included the creation of the functional concept taking into account business processes, the future authorization concept, data- and functional model, design of a prototype with regard to user requirements Phase 3: Implementation, Training & Testing During this phase the functional and the IT concept have been realized and the integration into the related SAP systems has been conducted. This was followed by the key-user training and the development of training materials. In addition extensive functionaland user tests have been conducted. Phase 4: Go-Live & Coaching Successful go-live of the productive system. Coaching of users and solving of issues.

5 _ Key project results System-supported production planning processes Full transparency over entire information flow in manufacturing Establishment of an overall centralized master data maintenance process for the SBU Eyewear Use of a graphical planning board for resource scheduling under consideration of availabilities and tools Results After only one year of intensive project work SAP ERP PP and APO PP/DS have been successfully implemented. The production planning and scheduling processes for eye protection at the Fürth plant were migrated from the AS / 400 legacy system to the newly introduced SAP system. Together with the IT system changeover the organization and the responsibilities for the master data process, the master data maintenance and the product calculation were redefined for SBU Eyewear. Important SBU Eyewear business processes within the uvex safety group as sales, disposition, production planning and scheduling, material supply, strategic and operative procurement, calculation, controlling and finance are now based on the integrated modules of SAP ERP and SAP APO. This will increase the transparency of business processes significantly and the data quality will be substantially increased. Statement With the decision to replace the AS / 400 production planning system with SAP technology, the uvex safety group has paved the road for achieving the ambitious growth targets and maintaining the competitiveness of the uvex safety group. Stefan Wehner Managing Director, uvex safety group

6 CAMELOT ITLAB Customer success story Your contact UVEX WINTER HOLDING GmbH & Co. KG The UVEX WINTER HOLDING GmbH und Co. KG is an almost 90 years family-run enterprise with headquarter in Fürth, north Bavarian. Uvex offers top-quality and innovative products that provide head-to-toe protection for sports, leisure and work. The uvex group heads up three internationally oriented divisions: The uvex safety group, uvex sports group with uvex sports and Alpina as well as Filtral. In the year 2012 the group generated a turnover of 343 Mio. Euros. UVEX WINTER HOLDING GmbH & Co. KG Friedemann Decker Head of Supply Chain Management SBU Eyewear & Head Würzburger Straße Fürth Phone Camelot ITLab GmbH Camelot ITLab is an independent, process-oriented IT consulting firm and a member of the Camelot International Group and provides its customers with combined strategy-, organizational- and IT-consultancy services. The experienced project teams are specialized in consulting and implementation of SAP applications, customer specific products and solutions as well as the development of innovative IT technologies. Through established and exclusive partnerships with well-known companies for example the SAP AG, Camelot consultants are kept up to date with the latest developments and standard of knowledge. Camelot ITLab GmbH Mario Baldi Managing Partner Camelot Management Consultants AG Patrick Wolf Partner & Key Account Manager Theodor-Heuss-Anlage Mannheim Phone