Case study:
How a material planner built a material planning process from the ground up
Assigned expert
Material planner
Challenge
No methodology. Inconsistent data. No SAP Key User.
An automotive manufacturing plant was operating without a structured material planning process. Material planners worked with inconsistent data, there was no standard methodology, and the plant lacked a dedicated SAP Key User for logistics and supply chain.
Without reliable master data, properly configured MRP parameters and standardized planning rules, material planning relied largely on individual experience. That increased the risk of material shortages, made decision-making more difficult and reduced the overall stability of production.
The main challenges included:
- no standardized material planning process,
- inconsistent master data and MRP settings,
- no SAP Key User support for logistics, purchasing and production,
- different planning methods used by individual material planners,
- the need to improve material availability and support stable production.
GQ solution
The objective was not simply to stabilize material planning, but to build a system that would continue to support the plant long after the project was completed. The transformation covered planning processes, master data, SAP support and the development of the internal team.
The project focused on four key areas.
1. Building the material planning process
- setting up complete master data,
- defining MRP parameters, including scrap rates, lead times and safety stock levels,
- configuring supplier scheduling, scheduling agreements and subcontracting processes,
- implementing customs procedures and ocean freight planning,
- standardizing material call-off processes.
Result: The plant established a fully functional material planning process for the first time.
2. Master data governance
- creating a centralized master data database for the entire supply chain,
- standardizing planning parameters across the plant,
- replacing individual planning practices with one consistent approach.
Result: Every material planner worked with the same data and the same planning rules.
3. Establishing the SAP Key User role
- taking responsibility for SAP Key User support across logistics, purchasing and production,
- building internal SAP expertise,
- training and handing over knowledge to the future in-house SAP Key User.
Result: The plant gained internal SAP expertise instead of relying on workarounds and ad hoc solutions.
4. Stabilizing material planning
- onboarding and training new material planners,
- creating standard work instructions,
- continuously improving and maintaining master data quality,
- stabilizing material flow across production.
Result: Materials were available when needed, preventing unnecessary production interruptions.
Result
- a fully established material planning process,
- reliable master data and properly configured MRP parameters,
- internal SAP Key User expertise for logistics, purchasing and production,
- standardized planning processes across the supply chain team,
- stable material availability with no production stoppages caused by missing materials,
- a logistics organization driven by data, facts and standardized processes.
Good material planning starts with reliable data
Material planning is about much more than ordering parts. It depends on accurate master data, well-configured MRP parameters, reliable SAP processes and a team working to one consistent methodology. This project proved that when those foundations are in place, material availability improves, production becomes more stable and supply chain decisions are based on facts rather than assumptions.
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