Clear production processes and greater inventory transparency in the production of cast products
Replacing a non-SAP production system is a prerequisite for the S/4HANA transition.
At a glance
Metal Industry
Headquarter Stadtallendorf
3,500 employees
966 million € turnover
The company
Fritz Winter Eisengießerei GmbH & Co. KG is a leading automotive supplier of iron castings. Since its founding in 1951, Fritz Winter has supplied cast products for drive and chassis technologies in the automotive, commercial vehicle, marine, and hydraulics sectors. Its main products are cylinder blocks, engine blocks, flywheels, and brake discs. These products are manufactured using highly specialized foundry processes. Production uses state-of-the-art equipment and technologies that meet the highest quality standards.
In addition to its four locations in Germany, Fritz Winter has two more companies in the United States and China, highlighting the company's international presence and competitiveness. With decades of experience, continuous innovation, and a clear customer focus, Fritz Winter has become one of the world's leading cast iron product suppliers.
Thanks to the new material levels and optimized warehouse structures, we now have clear stock transparency. This is the foundation for more efficient and simplified processes in the future.
Torsten Hinkelmann,
Head of Logistics at Fritz Winter
The challenge
Like many companies, Fritz Winter faced the challenge of converting its SAP R/3 environment to S/4HANA. The question arose as to whether the production process integration should occur simultaneously with the S/4HANA conversion. After a preliminary study, the decision was made jointly to first transfer production and production control from the current non-SAP system to SAP ERP. The complex foundry processes, with their specific casting regulations and historically developed structures, made this step particularly challenging. A lack of transparency in inventories and complicated booking processes made production control more difficult.
The goal was to simplify production processes, improve data quality, and lay the groundwork for the upcoming S/4HANA migration. Additionally, new material levels were introduced and organizational structures were adapted to make production more efficient. Previously, collective storage locations were used without systemic plant separation, which hindered inventory traceability and led to inefficiencies in production control.
The special requirements of sample and prototype production necessitated thorough adaptation and revision of production processes to meet complex requirements. Overall, the company faced a complex challenge involving technological and process-related changes that could not be overcome without comprehensive support.
The solution
abat provided external project management in addition to Fritz Winter's internal project management. They consulted on the SAP modules MM, SD, QM, PP, and PM and developed customized solutions for foundry-specific processes. Noteworthy is the conceptual design of the SAP LMPC Heijunka planning board, which replaces the previously used Excel lists with digital production planning. Individual adaptations were developed to meet the foundry's complex requirements and make production planning more efficient and transparent.
A prototype and sample process for transparent tracking across all product levels was developed and will be implemented after the initial launch. abat also supported the migration of master data and presented a proven start-up concept that Fritz Winter adapted to ensure a successful commissioning phase. SAP MII was used for operational postings on the shop floor. Another task to be mastered in the project was the integration of production confirmations between SAP ERP and SAP MII.
The project
It began with a preliminary study and a feasibility analysis to assess the mapping of production processes in SAP. Positive results led to the start of the project, which began with a joint kickoff of 16 subprojects. Initially, it was assumed that migrating the data would require little effort, but this proved to be a misjudgment. As the project progressed, new SAP plants were created, additional material levels were introduced, and processes such as production confirmations were optimized.
The originally planned go-live date was postponed by one year due to additional topics identified in the concept phase that required process optimization. The final implementation took place during an intensive cutover over a long weekend. During the subsequent two-week hypercare phase, any arising issues were addressed in shifts and resolved immediately, while employees were trained in the new processes. Close cooperation between abat and Fritz Winter characterized the course of the project, whereby optimization potential was continuously uncovered and implemented. Implementing the SAP LMPC Heijunka planning board and introducing it successively in the various production stages enabled flexible, needs-based production planning.
Migration of the master data was extensive because the existing data models had to be adapted in addition to the data transfer itself.
Additionally, reorganizing the warehouse structures provided a clearer overview and more efficient control of the production processes. Continuous collaboration with specialist departments, regular workshops, and flexible responses to unforeseen challenges also contributed to the project's success.
Comprehensive user support and the gradual expansion of the new functions supported the final stabilization. The entire rollout was carried out in close consultation with employees to ensure high acceptance and sustainable use in daily production. This project optimized manufacturing processes and production planning and created the basis for the upcoming S/4HANA conversion.
Outcome
Creation of increased inventory transparency
Increased process quality and stability
Streamlining of individual master data objects in the production area
Starting signal for system-supported production planning
Introduction of a consistent, cross-plant sample process in the SAP standard
The results
The collaboration between Fritz Winter and abat was characterized by mutual trust and a solution-oriented approach. Integrating the production processes into SAP ERP yielded tangible benefits: Individual master data objects became less complex, inventory transparency improved significantly thanks to new material levels, and booking processes simplified. Final optimizations to fully realize these benefits are still being implemented together. The gradual introduction of the SAP LMPC Heijunka planning board replaced manual planning in certain areas, increasing efficiency in production control.
This lays the groundwork for a seamless transition to SAP S/4HANA, promoting the sustainable optimization of production processes. Standardized processes ensure better traceability of production steps and make inventory management easier. Close collaboration between project partners has also led to lasting improvements in internal communication and greater acceptance of digital tools among employees.
Our collaboration with abat was characterized by trust and expertise. Together, we created the basis for our S/4HANA migration and optimized our production processes in the long term.
Alexander Schwab,
Head of IT & digitization at Fritz Winter