The product mix in this Iron & Steel industry client was extensive, as there was a possibility of any size of a steel sheet being in demand by customers. Variant configuration and its various possibilities required permutation and combination to incorporate all product size requirements. Process orders, product versions, recipes, and quality control design helped the client achieve true product costing and better production planning. This enabled them to handle high order loads efficiently and plan better product mix campaigns to maximize productivity without putting excessive stress on the plant and machinery system.

Plant maintenance was another area where significant improvements were achieved, enhancing plant availability through improved condition monitoring and preventive maintenance measures. Better spare part management was observed after SAP implementation by maintaining various stocks of spares and MRP data. This ensured better material availability in case of plant breakdowns and shutdown management situations. As a result, there was an improvement in MTBR (Mean Time Between Repairs) for critical production processing units like the 6-Hi Mill, 4-Hi Mill, Continuous Pickling Line, Continuous Galvanizing Line, and Colour Coating Line.