Deployment of a “Manuf” SAP solution in the United States

CONTEXT

A French pharmaceutical group that utilizes an SAP solution to support its business processes and back-office functions, primarily through logistics modules (MM, SD, PP, PM, PP, QM & WM) and Finance (FICO). This solution covers the Group’s various business lines (Manufacturing, Commercial, Shared Service Center) across its subsidiaries worldwide.

Following the acquisition of a new manufacturing site in Cambridge (USA), MeltOne was commissioned to deploy the “Manuf” solution at this new location. This solution covers manufacturing processes, warehouse management and logistics execution, quality management, and sales administration, as well as integration with Accounting and Controlling processes (CCR, inventory valuation, and cost analysis).

The challenges?

• Deploying a Core SAP Manuf solution aligned with the site’s needs and in compliance with group rules within a short timeframe
• Understanding and adapting the Core solution to support a new “BioTech” manufacturing model that differs from the Group’s other plants
• Transitioning from a paper-based quality justification system to an IT solution
• Integrating specific processes with the North American Shared Service Center
• The “Change” dimension through the information system—i.e., integrating group practices and onboarding resources during an external acquisition.

IMPLEMENTATION

MeltOne supported the integration of this site by defining and deploying its processes and data from Oracle/Paper to SAP, automating all workflows (transitioning from “paperwork” management to integrated operational flows).

The scope of this project included:

• Industrial issues such as warehouse definition and management
• Master data management and quality processes (quality control and steps, batch management, production dates, expiration dates, etc.)
• The manufacturing and subcontracting process for finished and semi-finished products, including requirements planning management
• Analysis of production costs and variances, and improved cost tracking
• Implementation of the intercompany sales process (buy-sell model)
• Analysis and drafting of IT documentation in compliance with IS validation rules in the healthcare sector (GxP)

SAP modules deployed: MM / SD / WM / PP / QM / FICO.

RESULTS

This new site has been deployed and live since January 2018. Manufacturing, storage, quality, and sales processes, as well as all accounting and analytical flows, are now managed within a single solution.

MeltOne supported them through their first month-end close; users are now trained and autonomous within the system.

The fixed-price budget and the schedule were both met.

Key figures:

• 1 fixed-price budget and 1 schedule met
• A project lasting less than 6 months
• A hybrid project structure (On-site/Remote) – More than 35 round trips between Paris and Boston
• An international project team of around thirty people, including 9 MeltOne consultants
• More than 70 end users