SAP Manufacturing Solutions & Industry 4.0 Architecture Consulting

SAP DM / DMC, SAP ME, SAP MII and Digital Transformation Consulting

Backed by more than 10 years of international MES Solution Architecture and Digital Manufacturing Management experience, we deliver enterprise consulting services covering conceptual blueprint design, S/4HANA and Level-2 automation integration, custom 3D digital twin development, cutover execution, and post-go-live hypercare.

01SAP DM / DMC Consulting 02SAP ME Consulting 03SAP MII Consulting 04Digital Transformation Management

Experience & Role: 10+ Years
International Portfolio: 8 Countries · 16 Plants
Delivered Implementations: 11 Full-Cycle
Custom Shop-Floor Modules: 23+ Custom Apps

Request Architectural Assessment Detailed Case Studies

Four Core Practice Areas

Our Consulting Services.

Architectural design, custom development, shop-floor integration, and production support across three generations of the SAP manufacturing execution portfolio (SAP DM / DMC, SAP ME, SAP MII) and plant-wide digital transformation programs.

SERVICE 01SAP Digital Manufacturing / Digital Manufacturing Cloud

SAP DM / DMC Consulting

3 Full-Cycle Implementations + Live Support

Cloud and hybrid manufacturing execution architecture integrated with SAP S/4HANA and S/4HANA Cloud Public Edition, custom SAP UI5 POD plugins, Process Orchestration services, and machine-layer connectivity.

SAP DM – PP (Production & Process)

Production and process order execution; BOM, routing, recipe, work-center, operation, and production-version integration; order release, yield/scrap, and confirmation postings; master and transactional data reconciliation between S/4HANA and SAP DM.

SAP DM – MM & EWM (Material & Warehouse)

Material master synchronization, component consumption, goods issue/receipt (GI/GR) movements, and root-cause error handling; EWM production supply, material staging, and shop-floor intralogistics flow.

SAP DM – PM / Asset Service

Execution of maintenance and service orders on the shop floor; bidirectional synchronization of order status, operation confirmations, and equipment notifications with ERP.

UI5 POD, CPI, PCo & BTP Analytics

Custom SAP UI5 POD extensions and plugins; SAP DM Process Orchestration custom REST services; SAP CPI & Communication Management; SAP PCo – DMC tag synchronization and Golden Batch activation; SAP BTP / SAP HANA Cloud data pipelines, OAuth2, initial load, delta replication, and cutover.

SAP DM / DMCS/4HANA PP · MM · PM · EWMSAP UI5 POD PluginsProcess Orchestration RESTSAP CPISAP PCo – Golden BatchSAP BTP · HANA Cloud

SERVICE 02SAP Manufacturing Execution

SAP ME Consulting

3 Full-Cycle Implementations + International Rollout

SFC-based unit traceability, operation control, custom POD operator interfaces, and multi-country plant rollout architecture for discrete and high-speed manufacturing environments.

Solution Architecture & Multi-Plant Rollout

Blueprint, fit-gap analysis, functional and technical specification; agile SAP ME architectural migration and rollout across manufacturing plants in Romania, Turkey, Belgium, and Morocco.

SFC Lifecycle & Unit Traceability

Shop Floor Control (SFC) order execution, split/merge operations, batch and serialization tracking, quality inspection/scrap/rework logging, and operator interlock validation rules.

Custom SAP UI5 Operator Cockpits & PODs

Adaptation of standard POD layouts for shop-floor ergonomics, custom UI5 operator panels, order visibility controls, and role-based workstation workflows.

ERP & High-Speed Equipment Integration

SAP S/4HANA and SAP ECC integration (LOIPRO production order IDocs, RFC, SAPMEINT message queues, and master data); SAP PCo and third-party automation connectivity on high-speed packaging and appliance assembly lines.

SAP MESFC TraceabilityMulti-Plant RolloutLOIPRO IDoc · SAPMEINTSAP UI5 PODSAP PCoCutover & Hypercare

SERVICE 03SAP Manufacturing Integration and Intelligence

SAP MII Consulting

5 Full-Cycle Implementations + Europe & Turkey Support

Real-time integration between ERP and Level-2 automation systems, BLS business logic transactions, 3D digital twins, custom UI5 operator cockpits, and HANA SQLScript optimization for heavy industry, steel, FMCG, and paper/converting plants.

SAP MII BLS, HANA SQLScript & UI5 Applications

SAP MII (15.3 / 15.4 / 15.5) implementation, Business Logic Services (BLS) transactions and QueryTemplate architecture, high-throughput HANA SQLScript stored procedures, and custom SAPUI5 operator and supervisory dashboards.

Iron & Steel (Meltshop & Rolling Mill) Digitization

Comprehensive technical architecture covering scrap yard, electric arc furnace (EAF), ladle furnace (LF), vacuum degassing (VD), continuous casting (CCM), reheating furnace camera/billet map, hot rolling main tower, NDT crack inspection, and 3D finished warehouse.

FMCG, Paper/Converting, 3D Digital Twin & 3D Warehouse

Solution/mixer (Drop) preparation, cellulose recipe combination, LGV autonomous reel logistics, centralized Inkjet coding, bulk palletizing, 3D Virtual Factory, and 3D Warehouse stock reconciliation for high-speed lines.

Level-2 Automation, PLC, Camera & Lab Instruments

Integration of SAP PCo, OPC UA / OPC DA, S7 PLCs, Level-2 automation servers (REST API, SOAP web services, JDBC), industrial barcode cameras (TCP/IP), optical emission spectrometers (13 elements + Cev), and mechanical tensile testing machines.

SAP MII 15.3 / 15.4 / 15.5MII BLS & QueryTemplateSAP HANA SQLScriptCustom SAPUI5 CockpitsSAP PCo · OPC UA / DAL2 Automation (REST/SOAP/JDBC)Three.js 3D Digital Twin

SERVICE 04Industry 4.0 Solution Architecture, IT/OT Governance & Program Delivery

Digital Transformation Management

10+ Years · 8 Countries · 16 Plants

Industrial digital transformation governance from current-state assessment to target architecture (ERP ↔ MES ↔ Digital Twin ↔ 3D Warehouse ↔ Level-2 Automation), technical program delivery, and production cutover.

Architectural Design, Blueprint & Fit-Gap Analysis

Mapping physical factory processes, analyzing gaps between IT and OT layers, and designing the target MES / Digital Twin / 3D Warehouse architecture tailored to plant constraints.

Program Governance & Multi-Plant Coordination

Scope management, technical team coordination, automation vendor alignment, and delivery quality assurance across concurrent multi-site manufacturing initiatives.

System Integration Testing, Cutover & Hypercare

Execution of comprehensive SIT/UAT test cycles, shift-handover rehearsals, production cutover playbooks, key-user training, and post-go-live hypercare stabilization.

Performance Audits, Queue Reconciliation & 24/7 Continuity

Database and SQL query optimization on live MES/HANA systems, automated ERP–MES consumption/confirmation reconciliation, and continuous 24/7 three-shift operational standards.

MES Solution ArchitectureBlueprint & Fit-GapIT / OT GovernanceGlobal RolloutHANA Performance OptimizationCutover & Hypercare

Live Shop-Floor Architectures

Sector-Specific SAP MII, SAP ME and SAP DM Custom Developments.

Beyond standard configuration: custom SAPUI5 operator cockpits, BLS transactions, HANA SQLScript procedures, and 3D digital twin applications engineered to solve physical shop-floor constraints in each industry.

Detailed Case Studies

SECTOR 01 · Iron & Steel · Meltshop and Continuous Casting (CCM)Shop-floor screen flow →

Meltshop Operations from Scrap and Hot Metal Charging to Continuous Casting and Billet Yard

Scrap Yard, Sinter & Torpedo Management, Electric Arc Furnace (EAF) / Converter (BOF), Ladle Furnace (LF), Vacuum Degassing (VD), 4-Strand Continuous Casting Machine (CCM) and Turnover Cooling Bed

STEP 01:Raw Material Preparation, Sintering and Hot Metal / Scrap Charging
STEP 02:Primary Smelting (Electric Arc Furnace / Converter) and Desulfurization
STEP 03:Secondary Metallurgy (Ladle Furnace - LF & Vacuum Degassing - VD)
STEP 04:Continuous Casting Machine (CCM) and Mixed-Grade (Intermix) Casting Management
STEP 05:Turnover Cooling Bed, Robotic Barcoding and Semi-Finished Billet Yard

Heat-Based Meltshop Cockpit and Automated Consumption/Output Confirmation: Single-screen management of heat orders, ferro-alloy additions and cut billet confirmations across EAF/BOF, Ladle Furnace, Vacuum Degassing and Continuous Casting stations.
Spectrometer Laboratory Integration and Intermix (Mixed Casting) Control: Instant comparison of optical emission spectrometer chemical results against steel grade tolerances and automated segregation of transition billets during sequence casting.
3D Meltshop Digital Twin with 1640°C Thermal Heat Map: Live 3D WebGL visualization of the entire meltshop from scrap yard and arc furnace to ladle/vacuum stations, 4-strand continuous caster and cooling bed.

SECTOR 02 · Iron & Steel · Hot Rolling Mill, Reheating Furnace and Wire Rod / Bar MillShop-floor screen flow →

Hot Rolling Mill Operations from Billet Charging and Reheating Furnace to Mill Stands, NDT and 3D Finished Warehouse

Billet Stockyard, Furnace Entry Camera & Weighing, 3-Zone Walking-Beam Reheating Furnace, Roughing/Intermediate/Finishing Mill Stands, Main Pulpit Tower, Cooling Bed, Cold Shear / Abrasive Saw, Eddy-Current / Ultrasonic NDT, Bundling and 3D Finished Goods Warehouse

STEP 01:Billet Selection, Overhead Crane Feeding and Furnace Entry Verification
STEP 02:Reheating Furnace Walking-Beam Tracking, 3-Zone Thermal Process and Billet Map
STEP 03:Hot Rolling Mill Line, Main Pulpit Tower and Specific Energy Monitoring
STEP 04:Cooling Bed, Cold Shear, Abrasive Saw Cutting and Surface/Crack NDT
STEP 05:Bundling, Strapping, End Painting, Labeling and 3D Finished Goods Warehouse

Furnace Entry Camera Verification and Billet Charging Interlock: Camera and weigh-scale verification of billets fed by overhead crane into the reheating furnace, preventing mixed-heat charging and preserving traceability for damaged tags.
In-Furnace Billet Thermal Map and SCADA – MES Reconciliation: Live slot-by-slot mapping of all billets inside the reheating furnace by position, order, heat color code, zone temperature and furnace dwell time.
3D Virtual Rolling Mill and 3D Finished Warehouse Visualization: Live 3D digital twin covering the billet yard, reheating furnace, rolling stands, cooling bed, saws, NDT station and multi-tier 3D finished goods warehouse.

SECTOR 03 · Fast-Moving Consumer Goods (FMCG) · Hygiene, Personal Care and High-Speed PackagingShop-floor screen flow →

FMCG Shop-Floor Management from Solution/Mixer Preparation to High-Speed Packaging, Palletizing and 3D Warehouse Flow

Chemical Solution & Mixer (Drop) Room, Primary Cutting/Folding & Liquid Filling Lines, Centralized Inkjet Coding, Secondary Case Packing & Palletizing, Elevator/Conveyor Transfer and 3D Raw Material / Finished Goods Warehouses

STEP 01:Chemical / Semi-Finished Solution Batching and Mixer (Drop) Process
STEP 02:Line Setup, Roll / Packaging FIFO Feeding and Sanitation
STEP 03:High-Speed Production, Filling, Centralized Inkjet Coding and OEE Andon
STEP 04:Secondary Packaging, Case Packing, Palletizing and Order Completion
STEP 05:Floor Buffer Stock, Elevator/Conveyor Transfer and 3D Finished Warehouse Putaway

Full-Screen 3D Digital Twin and 5-Stage Pallet Flow for High-Speed Lines: 3D virtual factory displaying all production and packaging lines, live PLC counters, OEE metrics and the 5-stage pallet journey from line end to finished warehouse.
Bulk Pallet Confirmation Engine and In-Memory FIFO Component Simulation: Single-action confirmation of multiple pallets during peak shifts with upfront FIFO component stock validation and automated label/posting orchestration.
Centralized Inkjet Coding and Mixer (Drop) – Line Traceability: Pairing solution batches prepared in mixer vessels with packaging lines and automatically driving line-mounted Inkjet printers from MES.
3D Warehouse Visualization, FIFO Aging and Quality-Blocked Stock Protection: 3D spatial management of all rack and bin addresses across raw material, semi-finished and finished warehouses with live stock, FIFO age and quality block status.

SECTOR 04 · Paper & Converting · Tissue Paper, Parent Jumbo Roll and Converting LinesShop-floor screen flow →

Shop-Floor Management from Pulp Blend and Paper Machine to LGV Autonomous Transfer and Converting Lines

Pulp Preparation & Pulper, Paper Machine (Tambour & Rewinder Slitting), LGV Autonomous Reel Transfer, Converting Lines, Statistical Quality Control (SQC) Laboratory and Finished Goods Warehouse

STEP 01:Pulp Raw Material Preparation, Furnish Blend Recipe and Chemical Dosing
STEP 02:Paper Machine — Tambour (Parent/Jumbo Roll) Winding and Rewinder Slitting
STEP 03:Reel Grouping and LGV (Laser Guided Vehicle) Autonomous Logistics
STEP 04:Converting Lines (Perforation, Embossing, Winding, Log Saw and Packaging)
STEP 05:Palletizing, Forklift Operations and Finished Goods Warehouse Management

Full Genealogy from Pulp Furnish Blend to Tambour, Parent Reel and Converting Pallet: Continuous material genealogy linking pulp blend ratios to Paper Machine tambour rolls, slit parent reels and finished converting pallets.
LGV (Laser Guided Vehicle) Reel Grouping and Autonomous Line Feeding Integration: Grouping heavy parent reels at the paper machine exit and dispatching LGVs for hands-free transport to intermediate storage and converting lines.
Plant Monitoring Cockpit, Statistical Quality (SQC) and Group-Changeover OEE Engine: Centralized supervision of live speed, order progress, Henkaten change points, SQC quality and OEE across all paper and converting lines.

SECTOR 05 · Discrete Manufacturing · Home Appliances, Electromechanical and Automotive Tier-1Shop-floor screen flow →

Shop-Floor Management from Press Shop and Body Prep to Multi-Station Assembly, Poka-Yoke and Functional Testing

Press Shop & Metal Stamping, Paint / Enamel Coating Line, Multi-Station Serial Assembly Lines, Smart Torque Nutrunner Stations, Electrical/Functional Test Booths and Line-Side Supermarket Areas

STEP 01:Press Shop, Metal Stamping and Sub-Assembly Cell Production
STEP 02:Body Preparation, Surface Treatment and Paint / Enamel Line Tracking
STEP 03:Multi-Station Assembly Lines, Barcode Component Validation and Poka-Yoke
STEP 04:Electrical Safety, Performance Test Booths and Closed-Loop Rework Routing
STEP 05:As-Built Unit Genealogy, Rating Plate Printing, Packing and Dispatch

Station-Based Operator Panels (POD) and Real-Time Poka-Yoke Interlock Engine: Real-time station validation architecture that halts progression when an incorrect component is scanned or an upstream operation is incomplete.
Automated Test Booth Integration and Closed-Loop Rework Governance: Automated capture of electrical and functional test rig results with enforced closed-loop rework routing for failed units.

SECTOR 06 · Electronics, Surface-Mount (SMD) PCBA and Precision Device ManufacturingShop-floor screen flow →

Shop-Floor Management from SMD Reel & Feeder Verification to AOI Inspection, Firmware Flashing and Device Assembly

SMD Component Supermarket, Solder Paste Printing & Pick-and-Place Lines, Reflow Oven, AOI / X-Ray Optical Inspection, ICT / Functional Test (FCT), Firmware Flashing and Final Box-Build Device Assembly

STEP 01:SMD Component Preparation, Reel-to-Feeder Verification and MSD Floor-Life Tracking
STEP 02:Laser PCB Marking, Solder Paste Printing, SMD Placement and Reflow Oven
STEP 03:Automated Optical Inspection (AOI / X-Ray) and Visual Defect Classification
STEP 04:In-Circuit Test (ICT), Firmware Flashing and Functional Calibration
STEP 05:Final Box-Build Device Assembly, Electronic As-Built Genealogy and Packing

Component Reel ID, Feeder Slot Interlock and MSD Moisture Floor-Life Governance: Verification architecture preventing wrong component reels from being loaded onto SMD feeders and blocking expired moisture-sensitive components.
AOI / Functional Test Integration and Complete Electronic As-Built Genealogy: Automated linking of optical and electrical test logs to board serial numbers and multi-level genealogy from component reel to final box-build device.

01 — Scope

What We Deliver

SAP DM / DMC (Digital Manufacturing): S/4HANA (PP, MM, PM, EWM) integration, UI5 POD plugins, Process Orchestration REST services, PCo–DMC connectivity, and Golden Batch.
SAP ME (Manufacturing Execution): Solution architecture, fit-gap analysis, SFC traceability, high-speed line integration, and multi-plant international rollouts.
SAP MII (Manufacturing Integration & Intelligence): BLS transaction development, UI5 operator cockpits, 3D Virtual Factory / Digital Twin, OEE/KPI reporting, and Level-2 automation (PLC, OPC UA, REST/SOAP/JDBC) integration.
Digital Transformation Management: Blueprint and target architecture design, IT/OT integration governance, technical project leadership, cutover execution, and hypercare support.

02 — Engagement Model

How We Work

Full-cycle project architecture: structured delivery from conceptual blueprint and fit-gap analysis through cutover and hypercare.
International multi-plant rollout and custom screen / process engineering for live manufacturing facilities.
Headquartered in Istanbul; operating remotely or on-site across Europe, MENA, and Turkey.

03 — Technology

Technical Stack

SAP DM / DMC, SAP ME, SAP MII (15.3 / 15.4 / 15.5), SAP BTP, SAP HANA & SQLScript, SAP UI5 & POD Plugins.
SAP S/4HANA & SAP ECC (PP, MM, PM/Service, EWM, QM, WM), S/4HANA Cloud Public Edition, SAP CPI, LOIPRO / BATMAS IDoc, BAPI/RFC, REST, SOAP, OAuth2.
SAP PCo, OPC UA / OPC DA, S7 PLCs, Level-2 Automation Servers (EAF/LF/VD/CCM), LGV Autonomous Vehicles, Barcode Cameras, Spectrometers & Mechanical Test Machines, Three.js 3D WebGL.

04 — Field Experience (8 Countries · 16 Plants)

SAP DM, SAP ME and SAP MII Project Portfolio Across Industries

Full-cycle implementations, multi-plant rollouts, and custom engineering engagements completed across Europe (Belgium, Italy, Germany, Netherlands, Greece), MENA (Algeria, Morocco), and Turkey.

Iron & Steel Meltshop & Continuous Casting (CCM) — Algeria & Turkey · SAP MII & HANA · Scrap/hot-metal charging, EAF/BOF converter, Ladle Furnace (LF), Vacuum Degassing (VD), and 4-strand CCM operator cockpits, spectrometer integration, mixed-grade casting rules, and 1640°C thermal 3D Meltshop Digital Twin.
Iron & Steel Hot Rolling Mill & Reheating Furnace — Turkey · SAP MII & HANA · Furnace entry optical camera verification, color-coded reheating furnace billet map, hot rolling Main Tower cockpit, cold shear/saw, NDT crack testing, bundling, and 3D Finished Warehouse.
Iron & Steel Wire Rod & Bar Mill — Algeria & Turkey · SAP MII & HANA · Billet yard crane tracking, rolling stand pass/groove management, coil weighing and tagging, hook-conveyor tracking, and open-yard / bay 3D inventory visualization.
Fast-Moving Consumer Goods & Hygiene (FMCG) — Belgium, Morocco & Turkey · SAP MII & SAP ME · Semi-finished solution/mixer (Drop) preparation, FIFO reel/packaging line feeding, centralized Inkjet management, live OEE Andon, bulk palletizing, and 5-stage 3D Pallet/Warehouse Digital Twin.
Paper, Tissue & Converting — Turkey & North Africa · SAP MII & SAP ME · Cellulose recipe combination screen, Paper Machine parent/buffer reel POD, autonomous LGV reel grouping, converting line POD, Statistical Quality Control (SQC), and Plant Monitoring Cockpit.
Home Appliances Multi-Plant Rollout — Romania & Turkey · SAP ME & SAP MII · Cross-country MES migration, serialized SFC unit tracking, station interlocks, LOIPRO/SAPMEINT queue synchronization, and high-speed assembly line integration.
Electromechanical & Aluminum Pressure Vessels — Turkey · SAP DM Solution Architecture · S/4HANA PP, MM, PM, and EWM integration, custom UI5 POD plugins, SAP CPI, and Process Orchestration REST services.
Electronics & Precision Manufacturing — Turkey & Greece · SAP DM & SAP ME · S/4HANA Cloud Public Edition integration, PCo–DMC machine tag synchronization, Golden Batch parameter verification, and component-level genealogy.
Industrial Machinery & Discrete Assembly — Germany & Italy · SAP DM / MII · Work-center POD customization, maintenance (PM) notification integration, tool life tracking, and OEE loss classification.
Food, Beverage & Packaging — Netherlands & Italy · SAP MII · Batch traceability, silo/tank level telemetry via OPC UA, automated goods receipt/consumption reconciliation, and shift performance reporting.

In accordance with corporate confidentiality agreements, client company names are omitted; all entries reflect delivered production architectures.

05 — Frequently Asked Questions

Frequently Asked Questions

We provide solution architecture, greenfield implementation, S/4HANA and Level-2 automation integration, custom UI5 / 3D digital twin engineering, and production support across SAP Digital Manufacturing (SAP DM / DMC), SAP Manufacturing Execution (SAP ME), and SAP Manufacturing Integration and Intelligence (SAP MII).

06 — Architectural Assessment

Schedule an Architecture Assessment

Request a scope and architecture review session for your SAP DM / DMC, SAP ME, SAP MII, or shop-floor digital transformation initiative.

Request Architectural Assessment