ManufacturingSAPSupply Chain &Data-Driven Decision Intelligence

S/4HANA Transformation for Smart Manufacturing

Fortune 500 Manufacturer

45%

Improvement in Production Planning

30%

Reduction in Inventory Costs

99.8%

Data Migration Accuracy

Real-time

Supply Chain Visibility

Business Context

The organization and its strategic environment

A $12B Fortune 500 manufacturer with 28 plants across North America faced SAP ECC end-of-support deadlines. The company's production planning relied on spreadsheets, supply chain visibility was limited to 48-hour windows, and inventory carrying costs were $180M annually.

Technology Landscape

Systems and infrastructure before DGT

SAP ECC 6.0 with 1,400+ custom ABAP programs, 6 bolt-on MES systems, Oracle data warehouse, manual production scheduling in Excel, and limited EDI connectivity with 200+ suppliers.

The Challenge

What the client was facing

Heavily customized SAP ECC 6.0 facing end-of-support, spreadsheet-based production planning causing 12% schedule adherence gaps, 48-hour supply chain visibility windows, and $180M in excess inventory carrying costs.

The DGT Solution

How DGT addressed the challenge

DGT executed a greenfield S/4HANA implementation with embedded analytics, integrated MES connectivity, real-time supply chain visibility, and AI-powered demand sensing. DataBridge migrated 14 legacy systems with 99.8% accuracy.

DGT Accelerators Used

DataBridgeInsights360

Delivery Approach

How DGT executed the engagement

Big-bang go-live approach with 6-month parallel run. DGT deployed a 22-person team across functional and technical workstreams. Weekly cutover rehearsals for the final 8 weeks ensured zero-downtime go-live.

Governance Model

How the engagement was managed

C-suite steering committee (monthly), program director with DGT and client co-leads, 6 functional workstream owners, weekly risk register review, and dedicated cutover command center.

Timeline & Phases

The execution roadmap

Discovery & Blueprinting

6 weeks

Fit-gap analysis, custom code remediation plan, data migration strategy

Core Build

12 weeks

S/4HANA configuration, MES integration, supplier portal

Data Migration

4 weeks

DataBridge migration of 14 systems, 3 mock cutovers

Testing & Validation

6 weeks

Integration testing, performance testing, UAT across 28 plants

Go-Live & Hypercare

6 weeks

Big-bang cutover, 24/7 war room, stabilization

Risks Addressed

Key risks DGT mitigated during the engagement

1,400+ custom ABAP programs requiring remediation or retirement

Big-bang go-live risk across 28 plants simultaneously

Data migration from 14 heterogeneous source systems

Production continuity during cutover weekend

Why DGT Won

What set DGT apart in this engagement

DataBridge accelerator reduced migration timeline by 40%

Prior S/4HANA greenfield experience in manufacturing

Zero-downtime go-live methodology proven across 5 prior migrations

Insights360 delivered executive dashboards within first sprint

Outcome Metrics

Measurable before-and-after results

Metric	Before	After DGT
Schedule Adherence	78%	94%
Inventory Carrying Cost	$180M/yr	$126M/yr
Supply Chain Visibility	48 hours	Real-time
Custom ABAP Programs	1,400+	180 (87% retired)

The Impact

Headline results delivered

45%

Improvement in Production Planning

30%

Reduction in Inventory Costs

99.8%

Data Migration Accuracy

Real-time

Supply Chain Visibility

"DGT's DataBridge accelerator made our S/4HANA migration seamless. We went live on schedule with zero data quality issues."

David Park

CIO, Fortune 500 Manufacturer

Could This Work in Your Environment?

Let's discuss how DGT can deliver similar outcomes for your enterprise. Book a session to walk through your specific challenges.