Vertical integration in the plastics industry

Growth through highly integrated core processes

Goals
Senoplast, a plastics extrusion company of the Klepsch Group from Salzburg, wanted to replace the existing AS400 ERP solution and in-house developments in production with SAP ERP and conMES, our MES solution based on SAP MII. The project was implemented together with Phoron, with concircle being responsible for conFIGURE (rule-based solution for variant configuration), PP including a block planning solution, conMES and 7 Fiori Apps in the warehouse. The project was implemented between 2017 and 2019, the roll-out to China and Mexico was completed in 2020.
Solution
The modernization of the processes was carried out on the basis of the following solutions.
  • SAP ERP Standard​ (PP, SD, CO, MM, WM)
  • conFIGURE
  • conMES
  • SAP UI5
Challenge
The extensive product range of multi-layer, co-extruded plastic sheets and rolls in combination with a wide variety of ready-made sizes required a flexible solution for product specification that was integrated into the sales process, planning and controlling. A high level of customer service results in a wide variety of MTO lot sizes, so that planning must form optimized setup blocks for the lines based on key product and process parameters. For complete material balances, taking into account recycled material and rejects, all lines have to deliver order-specific consumption measurements to MES.
Benefits
Senoplast can now continue its successful international growth course on the basis of a fully integrated system with optimally coordinated processes from plant control to sales. Functions such as dynamic work plan and recipe generation or the system connection for consumption quantity determination help to make processes more efficient in all areas.

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