Migration from SAP ECC to SAP S/4HANA for a Developer & Supplier of Optical Fibers and Laser Systems

The LeverX team supported the client in digital transformation to SAP S/4HANA to drive higher performance and process automation.

Client

A global developer, manufacturer, and supplier of optical fibers, fiber bundles, cables, and laser delivery systems for advanced scientific, industrial, and medical applications.

Project Background

Accurate scheduling and process control are essential for the client’s large and growing business. Their manufacturing workflow consists of several key stages, all of which must be centrally monitored and managed in real time:

• Engineering and design 
• Technology development 
• Fiber production 
• Mechanical parts production 
• Assembly 
• Packaging 
• Logistics

Previously, the company operated on an older, on-premise ERP system — SAP Enterprise Central Component (SAP ECC). Within the manufacturing industry, SAP ECC supported key business functions, including resource planning, inventory management, procurement, and production quality control.

This solution supported the customer for years by improving control over manufacturing processes, ensuring operational efficiency and quality compliance, and enhancing overall productivity.

To drive higher performance and process automation, the customer required a digital transformation to SAP S/4HANA. This transition enables the following key enhancements:

Regulatory compliance

Supports adherence to regulatory standards by providing tools for managing compliance-related processes, including product labeling, documentation, and traceability.

Quality management

Helps ensure product quality and compliance with industry standards through functionalities for quality planning, control, inspection, and non-conformance management.

Supply chain management

Improves supply chain visibility and efficiency by enabling better demand planning, procurement, inventory management, and logistics, as well as optimizing inventory levels.

Analytics and reporting

Enables real-time data analysis with in-memory computing, offering dashboards and reporting tools to support data-driven decisions and continuous process optimization.

Project Scope

The LeverX team carried out the full transformation cycle, taking end-to-end responsibility for the system migration — from infrastructure setup to all stages of the migration process. Working in close collaboration with the customer’s management team, the goal and strategy were clearly defined, according to their expectations and background information on previous functionalities and processes. LeverX also documented the project milestones and requirements in detail.

The migration had to be completed within a tight three-day holiday window, the only time the system could be paused without disrupting daily operations. This was crucial for the client, as any interruption in the medical manufacturing workflow could lead to missed deliveries — a critical risk in medical and pharmaceutical industries.

Moreover, the customer had custom-developed code integrated into the previous system version. These components needed to be carefully modified, migrated, and adapted to ensure full compatibility and seamless operation within the new SAP S/4HANA environment.

The project followed the SAP Activate methodology. To transition to SAP S/4HANA, the LeverX team applied the Brownfield system conversion approach, which enables the transfer of all data from the existing SAP ERP system to SAP S/4HANA. This method is commonly favored by manufacturing companies, as it ensures a smoother migration with minimal disruption to ongoing operations. It builds upon the existing SAP system landscape, preserving current configurations, custom developments, and business processes. 

Compared to the Greenfield (full reimplementation) approach, Brownfield typically offers a shorter implementation timeline — a key factor in this project. 

The process included the migration of several ERP modules to the SAP S/4HANA system:

Following the successful migration, the LeverX team integrated an additional SAP S/4HANA tool — Production Planning and Detailed Scheduling (PP/DS). This solution enhanced the client’s capabilities in production planning, delivery coordination, and operational efficiency. With PP/DS, the client can now accurately analyze inventory levels, plan resources with greater precision, monitor production order progress in real time, track performance against schedules, and quickly identify bottlenecks or delays. 

Project Results

The LeverX team successfully completed the full data migration from the legacy SAP ERP system to SAP S/4HANA within the planned timeline. The client continues to operate on SAP S/4HANA and maintains an ongoing partnership with LeverX through support projects, where we provide assistance with additional system configurations and enhancements.