CLIENT CONTEXT

Zhaochi Group is a large-scale discrete manufacturing company in consumer electronics and LED manufacturing. Its operating environment spans multiple factories, production lines, product units and teams across planning, procurement, material control, production, quality and warehousing.

The case shows how an SAP-based manufacturer can connect sales order data in SAP with MES production progress, giving management one shared view from order intake to production execution and shipment.

BUSINESS CHALLENGES

Before the Guandata project, Zhaochi's sales order data was managed in SAP, while production work-order progress was tracked in MES. Data was separated across factories and organizations, and some operational information still relied on manual collection and reporting.

To understand one order, teams had to check multiple systems across sales order creation, planning, material readiness, work-order execution, quality inspection, warehousing and shipment. This created coordination cost, inconsistent information and slower response to production exceptions.

GUANDATA SOLUTION

Guandata helped Zhaochi build a manufacturing operations analytics layer on top of existing SAP, MES and other operational systems. The solution integrated SAP sales order data, MES production progress and related ERP, PLM, OA and manual data into a layered manufacturing management system.

Core workflows include order lifecycle tracking from sales order to planning, work-order execution, quality inspection, warehousing and shipment; production plan achievement monitoring across factories and business units; material readiness / kitting visibility, including missing materials, in-transit quantity and planned arrival date; quality and efficiency analysis at factory, workshop and production-line level; and exception alerts related to production-plan deviation, material shortages and quality issues.

SELECTED ANALYTICS SCENARIOS

BUSINESS IMPACT

Through the Guandata analytics layer, Zhaochi gained a shared operational view of order execution and production delivery. Planning, procurement, material control, production, quality and warehouse teams can monitor order status, material readiness, production progress and exceptions in one layer instead of relying on fragmented reporting and manual cross-checking.

The project helped reduce coordination bottlenecks and enabled earlier response to production exceptions across planning, materials, production, quality and shipment workflows. It also supported more timely manufacturing decisions by connecting order, plan, material, production and quality views. In one inventory-warning scenario, stagnant material ratio was reduced from 5% to 3%.

DATA & PROCESS SCOPE

Source systems connected: sales order data in SAP; production progress data in MES; ERP, PLM, OA and manual operational data.

Management layers covered: group, business unit, factory, workshop and production line.

KEY TAKEAWAY

This case shows how Guandata adds a manufacturing operations analytics layer on top of SAP, MES and other systems to connect orders, materials, production progress and exceptions.