The task: Use the SAP standard with no functional compromises

Implementing standard software into the components factory's complex workflows was an enormous challenge for the project management team. The existing processes in many different areas were to be harmonised with the SAP standard – without making any functional compromises. Apart from planning and implementing the software solution, it had to be ensured that the software would interact perfectly with the hardware: "We were responsible for the entire system – in other words, also for the WLAN connection and configuration of the handhelds," says Gerhard Schamberger, Team Manager Logistics at Cirquent GmbH.

The solution: Customer-specific solution with SAP WM and radio data transmission

The first thing the project team - consisting of Cirquent consultants and experts from the BMW Group - did was to analyse the existing organisation and processes so that they could be mapped in SAP. "We were able to integrate the streamlined processes into an existing SAP landscape with no functional compromises and to remain fully within the SAP standard," explains Gerhard Schamberger. "During the planning phase the advantages of radio data transmission became increasingly obvious." When the detailed concept was accepted, we also decided to use RDT.

The BMW Group split the project into three phases: The different areas "wheel sets", "gearbox" and "flanges" were to be changed over to SAP successively in order to minimise potential risks. In the subsequent implementation phase the entire process had to be mapped in SAP WM Version 4.6c in terms of the system technology. "There was only one instance where we didn't stick to the standard and carried out our own programming: the input screen of the handhelds," says Schamberger. BMW Group employees had to get the main information they needed on the small handheld display without having to scroll or change screens. Therefore, Cirquent consultants ensured that the screens display the required fields for the specific roles.

The benefits: Optimise material supply through to the assembly belt

The solution, which was planned and implemented by Cirquent in close collaboration with BMW Group staff, ensures maximum transparency for every component: stocks, storage locations, information about where and when the part was made, etc. This allows the car manufacturer to optimise its inventories. The warehouse management processes for the manufacture of the rear axle differentials in the Dingolfing components factory are fully supported: including feedback from the production department to delivery at the installation location in the assembly plant. End-to-end use of Radio Frequency Terminals completely prevents media interruptions.

Reduce inventories by up to 50 per cent

Thanks to optimised warehouse management efficiency and transparency in the production were quickly and noticeably improved. With the consistent use of SAP standard software the IT system landscape became more maintenance friendly and future proof. Warehouse management for rear axle differentials in the Dingolfing components factory was integrated seamlessly into the existing and future system landscape of the BMW Group. Inventories were reduced considerably – in some cases by up to 50 per cent.