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Maha Maschinen-
bau Haldenwang

MAHA Maschinenbau Haldenwang |
S/4HANA Implementation

in the SAP modules PP, PP/DS and BDE

Highlights of the implementation

  • 1:1 mapping of a non-SAP legacy system using SAP standard and additional developments
  • Development of a cross-project master data migration program
  • Full PP/DS planning including procurement planning in MRP and setup optimization as part of PP/DS optimization
  • Implementation of a customized, user-friendly PDA solution
90000
Material masters
7000
Production orders
100
+
Resources
7
Disposal stages

Starting point

At its production site in Haldenwang, MAHA manufactures products for vehicle testing and lifting technology, the end products being configurable performance and brake test stands. The spare parts business is also an important part of the business.

Before the start of the project, MAHA was using a heavily modified version of the Baan V4 ERP system, which meant that any upcoming update could only have been carried out with a great deal of effort. At this point, CONSILIO came into play through a customer recommendation.

Project goal

After recording the actual processes, CONSILIO compared the requirements with the SAP modules and programs as part of the required planning solutions. The main focus was on the SAP PP, PP/DS and BDE modules. The evaluation of the results showed that the aforementioned requirements for master data, planning and production control can be mapped in the SAP standard system or by means of additional development.

The aim of the main project is to implement the SAP modules PP, PP/DS and BDE in S/4HANA and to provide the previous functionalities of the non-SAP legacy system 1:1.

Thanks to CONSILIO's professional support, we can successfully replace our legacy system and take full advantage of the strengths of the SAP standard and CONSILIO solutions under S/4HANA.

Roy Lazonby, Head of IT CIO MAHA Maschinenbau Haldenwang GmbH & Co. KG

Challenges

The first step was to replace the planning run in the Baan system. Planning was set up from scratch in the PP/DS area. To do this, planning-specific data had to be converted from Baan to SAP APO or PP/DS rules. It was necessary to define which complementary PP/DS settings existed for the settings stored in Baan, such as planning and lot-sizing procedures, and to implement them accordingly. In the area of PP, complex mappings were required for a successful migration of the master data so that the Baan data could be assigned to the correct SAP fields. This was achieved using a sophisticated migration programme and the corresponding implementation rules.

This was followed by the creation of concepts and the implementation of further requirements in the area of PP/DS, as well as an update of the CIF integration. The infinite planning run and the optimisation were set up using sample data. This enabled comprehensive PP/DS planning in APO, including procurement planning in MRP and setup optimisation as part of PP/DS optimisation.

Another requirement was that processes be kept together across orders and for different products. This occurs primarily with left- and right-hand parts and means that different products must be available at a resource or workstation at the same time for assembly, although each product has its own order. In PP/DS, this requirement can be met with an additional development and by using external assignment relationships.

Furthermore, MAHA uses a feedback terminal that is to be completely replaced by a new BDE solution. However, the SAP BDE module in its standard form – and also in the upcoming S/4HANA Release 2020 – does not meet MAHA's requirements. Therefore, these must be mapped using a new BDE solution and their own Fiori apps.

Function and advantage of the solution

Both SAP standard and CONSILIO add-on solutions were implemented in the project. MAHA has opted for a package with the following CONSILIO solutions in the module areas PP/DS, PP and BDE:

Module area PP/DS

CONSILIO solution ‘Critical Path’ with context view backend and UI5 frontend: In the SAP standard system, it is almost impossible to determine the critical path with reasonable effort, especially with large order structures. The CONSILIO solution for determining the critical path is implemented directly in the context view of PP/DS, visualising internal and cross-order buffers and cumulating them across all MRP levels. The critical path can also be visualised in a separate UI5 application.

Module area PP

CONSILIO solution ‘Change documents in the production order’: The modification-free add-on solution, implemented via a customer-specific change document object, offers the option of both logging and evaluating data changes to the order header, operations, components and production aids. All desired fields and those contained in the order tables can be included in the logging. A quick analysis of the changes is possible by comparing the old and new field contents.

Module area BDE

CONSILIO feedback transaction: The previously used feedback terminal is completely replaced by the new, user-friendly CONSILIO solution. The web UI allows direct logon to the terminal, feedback can be provided and user-specific data can be viewed according to authorisations. The feedback is synchronised with the SAP standard feedback transactions. Replacement chains for discontinued products, the alert monitor and the S/4 Fiori planning board were also set up as part of the package.

MAHA Maschinenbau Haldenwang GmbH & Co. KG

  • Industry: mechanical engineering
  • Business area: MAHA manufactures a complete range of solutions and products for motor vehicle testing and workshop equipment at its production sites in Haldenwang and Pinckard (USA).
  • Web: www.maha.de
  • SAP solution: S/4HANA 1909
  • Consulting partner: CONSILIO GmbH

Further information

SAP PP/DS & ePP/DS

SAP PP/DS & ePP/DS

Production planning: integrated optimisation & detailed planning in S/4HANA

Production planning with SAP (SAP PP)

Production planning with SAP (SAP PP)

We will support you on your journey to transparent, streamlined and innovative production planning.

S/4HANA Transformation

S/4HANA Transformation

Your customised roadmap for the switch to S/4HANA