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Where production plans break before they reach the floor.
When your operation runs on files scattered across people, on rules that only live in someone's head, and on patches layered onto an ERP that was never meant to carry them, decision quality collapses before a single order is launched.
Master data no one trusts.
Product records, routes, resources and suppliers live in different files, different systems and different hands. BOM explosions come out wrong. Orders launch with the wrong variants. Planning spends half its week reconciling data that should have been clean from the start.
Business impact
Higher operational cost, lower delivery reliability, margin lost to errors nobody wanted to make.
A forecast that arrives late, or doesn't arrive aligned.
Product records, routes, resources and suppliers live in different files, different systems and different hands. BOM explosions come out wrong. Orders launch with the wrong variants. Planning spends half its week reconciling data that should have been clean from the start.
Business impact
Lower service levels, more urgent requests, less confidence when committing to delivery dates.
Purchasing disconnected from real need.
Rush orders. Manual adjustments. Stock that doesn't match demand. Priorities decided more by habit than by data, and by whoever shouts loudest that week.
Business impact
Capital tied up in wrong inventory, procurement overruns, stockouts that cost sales.
Business rules hidden in your planner's spreadsheet.
How orders get aggregated. How substitute materials get chosen. How lot sizes get decided. The logic that actually runs the factory lives in a workbook on one person's desktop — and when that person is out, the factory slows down.
Business impact
Dependency on specific people, zero auditability, no scalability when the business grows.
Every tweak to the plan means another patch on your ERP.
Custom code in PP. Custom fields in MRP. Adjustments layered on top of adjustments. Every upgrade becomes a project of its own. Every change becomes a negotiation with IT. The path to S/4HANA gets harder with each new patch.
Business impact
Technical debt compounds, upgrade cycles stretch out, clean-core migration becomes a bigger problem every year.
The plan that leaves the ERP isn't the plan that reaches the plant.
Scheduling reinterprets. MES fills in the blanks. The plant adjusts on the fly. By the time the order is actually executed, nobody can reconstruct why it came out the way it did.
Business impact
Lower productivity, missed deliveries, decisions nobody can defend when things go wrong.
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