Plan versus reality
Production plans built on standard routings that no longer match how the line actually runs, so schedule adherence gets reported rather than achieved.
Discrete manufacturing
Production that reflects what's actually on the floor
SAP for discrete manufacturers — where the plan, the shop floor and the ledger have to agree, and usually don't. We bring both the SAP side and the industrial automation side of the integration.
What we see in this sector
Sector-specificpressures
Disconnected shop floor
Machine and line data living in systems SAP cannot see, so confirmations are entered by hand hours after the fact.
Unplanned downtime
Maintenance that stays reactive because asset history is incomplete — and incomplete because recording it is a chore nobody owns.
Costing that lands late
Actual product cost known weeks after the period, by which point the pricing decision has already been made.
Where the gap usually is
The ERP knows what was planned. The floor knows what happened. The gap between them is where margin disappears, and it is almost always an integration problem rather than a planning one.
Closing it means getting confirmations, scrap, downtime and quality results into SAP as they happen rather than at the end of a shift — which is an engineering problem on the machine side as much as a configuration problem on the SAP side.
That combination is unusual in an SAP partner, and it is why manufacturers come to us specifically.
Frequently asked
Common questions frommanufacturing leaders
What SAP modules do you implement for discrete manufacturers?
Core production coverage is SAP S/4HANA PP, PP-PI, QM, PM, MM, SD and CO-PC. Add-on modules include EWM for warehousing, Digital Manufacturing Cloud for shop-floor orchestration, and Asset Performance Management for predictive maintenance.
Do you handle shop-floor integration with SAP?
Yes — this is where our joint work with PN Automation differentiates. We cover PLC / SCADA integration, OPC UA, MQTT and SAP Plant Connectivity through to IDocs or Event Mesh into S/4HANA. The engineering and the configuration sit in one team, not two.
How long does an SAP implementation for a manufacturing plant take?
A single-plant greenfield S/4HANA runs 8–14 months end-to-end depending on integration scope. Multi-plant rollouts after the template is stable typically compress to 3–5 months per site.
Can you deliver predictive maintenance with SAP?
Yes. We combine SAP Asset Performance Management with sensor telemetry, Plant Maintenance history and ML-based failure prediction. The model lives where the data lives — HANA, typically — not in a separate analytics silo.
Next step
Working in manufacturing? Let's compare notes.
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