Novità
Indicare la sintesi delle news
From Dowel Quality to Logistics Excellence
16.05.2025
Successful Transformation from SAP WM to SAP EWM/TM at fischerwerke During Ongoing Operations.
The fischer Group of Companies, in collaboration with SAP engineers from IGZ, has migrated its logistics at the main site in Tumlingen to SAP Extended Warehouse Management (SAP EWM) and SAP Transportation Management (SAP TM). This migration was carried out using a Big Bang approach, successfully completed over a single weekend.
By implementing SAP EWM and SAP TM, fischer not only enhances efficiency but also increases flexibility while guaranteeing a 99 percent same-day processing rate. This transition lays the foundation for future innovations and expansions of logistics processes. The over 20-year partnership with IGZ was a decisive success factor and forms the basis for further optimizations and rollouts.
fischer – A company with tradition and innovative strength
The traditional company fischer, headquartered in Tumlingen, Baden-Württemberg, is among the world’s leading providers of fastening technology. As a family business that invented the dowel over 70 years ago, fischer stands for innovation and exceptional quality.
Today, the product portfolio includes fastening systems, fischertechnik, as well as customized complete solutions in the areas of Electronic Manufacturing Services (EMS) and touch input systems.
Additionally, the company offers valuable consulting expertise in process optimization through fischer consulting. With approximately 4,700 employees worldwide and a strong international network spanning 120 countries, the company achieved gross sales of 1.16 billion euros in 2023.
Efficient Logistics at the Tumlingen Distribution Center
The Tumlingen Distribution Center (DCT) serves as a hybrid warehouse and acts as a central regional warehouse for Germany and France, as well as a replenishment warehouse for national subsidiaries and importers. On peak days, around 26,000 delivery positions are processed.
The warehouse is characterized by high complexity and utilizes a variety of modern storage technologies within limited space: an automated high-bay warehouse (HRL) with 14,250 pallet spaces and a shuttle system with 21,500 containers. In the extensive manual picking area, approximately 3,800 positions are processed daily.
With about 11,000 stocked items and a three-shift operation – including a continuous night shift for internal replenishments and pre-picking – the operation is maintained at a high level. The entire goods receipt and dispatch process is handled within just 300 m². Annually, around 120,000 packages and over 8,000 trucks are processed with the help of SAP EWM and SAP TM. Ergonomic workstations with vacuum lifters and innovative depalletizing technology significantly contribute to process efficiency.
Challenges and the Need for Transformation
By 2020, it became evident that the existing system architecture could no longer meet growing market demands and internal growth objectives. The SAP ECC 6.0 system in use was approaching its end of maintenance, creating an urgent need for action. The existing SAP WM solution, optimized over more than two decades, showed increasing age-related limitations, particularly in warehouse management and material flow control.
Material flow control was managed via SAP LES/TRM and a second complementary external warehouse management system, but modern interfaces for seamless data exchange were lacking. Additionally, extended requirements for transport logistics could not be met with the previous, already discontinued SAP LE-TRA solution.
Given these circumstances, fischer decided to switch to a modern and flexible system that not only meets current requirements but also offers innovation potential for the future. »The project goal was quickly clear«, emphasizes Jörg Schröppel, Head of IT Business Solutions at fischer. »Key objectives included reducing reliance on non-standard functions, meeting new strategic requirements, and establishing a solid foundation for future innovations.«
The implementation of an S/4HANA-compatible solution was identified as the key to enhancing efficiency in warehouse and transportation processes, ensuring a consistent 99 percent same-day processing rate.
Demanding Projects Require Strong Partners
Against this backdrop, the decision was made to partner with IGZ for the project implementation. Jörg Schröppel comments:
»We knew that a project of this scale could only be successfully implemented with a reliable and competent partner. The long-standing collaboration with IGZ and their expertise in implementing modern, scalable systems made the decision obvious. Moreover, IGZ enjoys an excellent reputation in the market, further simplifying the choice. Together, we aimed to create a future-proof and high-performance system architecture that meets the dynamic requirements of the market while providing room for future expansions.«
Optimizing Warehouse Logistics with SAP EWM and TM: Is There More to Achieve?
»Optimizing warehouse logistics, particularly through the implementation of SAP EWM, MFS, and TM, proved to be more complex than initially expected«, explains Julian Bauer, Deputy Head of SAP Warehousing at IGZ. »The warehouse already had an extremely high occupancy rate, raising the question of whether further improvements were even achievable solely through the transition to SAP EWM.«
One of the greatest challenges was maintaining the existing logistics performance despite the transition and the reintegration of numerous custom programs into the SAP standard. A rapid transition success was necessary to ensure the accustomed 99 percent same-day processing rate.
By the second day after the go-live, 90 percent was already achieved. The high daily delivery volumes – with peaks of up to 26,000 positions – also posed demanding challenges for the project team.
Conclusion: Flexibility and sustainability through automation
The introduction of SAP EWM/MFS and SAP TM replaced numerous functions of the old SAP WM and SAP LE-TRA (SD), allowing material flow control to be managed directly via EWM. The other warehouse management system for the container shuttle remains in place; however, its integration has been optimized for improved transparency and efficiency. »We are already developing concepts on how to further integrate these processes in the future«, explains Jörg Schröppel.
In the transportation sector, SAP TM enabled the successful reintegration of various custom solutions and third-party systems – such as invoice verification – back into the SAP standard. Cleverly designed order loading and package and load space calculations led to significant efficiency gains in internal material flow and transportation control. Continuous integration between SAP EWM and SAP TM was implemented to enable seamless processes. Additionally, freight cost management is now executed by SAP TM with features such as cost splitting and automated invoice verification.
The modernized user interfaces allow for more intuitive operation. The IGZ Smart Logistics Cockpit, a proactive Fiori control center, provides employees with real-time overviews and alerts for efficient daily capacity planning and rapid response to material flow disruptions. The Fiori picking app supports the picking process in a user-friendly manner, while innovative technologies such as back-of-hand scanners contribute to increased efficiency and reduced errors.
Successful Go-Live and Comprehensive Support
To ensure a smooth go-live, all functions and processes were thoroughly tested in advance using the IGZ Digital Twin. This virtual representation of the warehouse and its processes enabled comprehensive software testing without jeopardizing the company's delivery capabilities.
During the go-live weekend, when order volume was at 60-70 percent, an extended project team provided comprehensive support, allowing the migration to SAP EWM/MFS and SAP TM to be successfully completed using a Big Bang approach.
Conclusion
»The implementation of SAP EWM/MFS and TM, combined with tailored adjustments, has significantly improved warehouse and transportation logistics at fischer and forms the foundation for future optimizations in the supply chain«, summarizes Jörg Schröppel.
The newly established IT infrastructure now enables fischer to expand logistics processes for additional national subsidiaries in a future-proof manner. An initial follow-up project – the EWM/TM rollout and the construction of a new AutoStore warehouse in Spain – is already underway.
Orginiale source: