PLM Modernization and Process Harmonization for a Global Hygiene and Infection Prevention Company

We helped the customer reduce cycle times and increase capacity, allowing manufacturing to begin sooner.

Client

A leading global manufacturer specializing in hygiene and infection prevention solutions. As the company expanded through acquisitions and growth across regions, its product and specification data landscape became increasingly complex.

Challenge

As the organization grew and integrated newly acquired businesses, managing end-to-end product data across multiple divisions and regions became increasingly difficult. Different regions and legacy companies used their own specification processes and systems, which led to:

• Fragmented processes across divisions, regions, and legacy companies
• Multiple, disconnected PLM and specification tools, including a legacy EPIC-based PLM system
• No single source of truth for specification data, with information spread across silos
• Longer time-to-market due to manual steps and inconsistent workflows
• Reduced visibility into product data across functions and locations
• Quality and regulatory compliance risks stemming from non-standardized processes

Maintaining a unified PLM environment was essential, but this was challenging in such a fragmented landscape. The company needed to consolidate product-related data, harmonize processes, and replace its legacy EPIC PLM system with a modern, integrated platform.

Solution

LeverX recommended SAP Product Lifecycle Management (SAP PLM) as a modern alternative to the client’s legacy EPIC PLM system. SAP PLM was selected as the central platform to consolidate all product-related data within a single, scalable environment and to support standardized, end-to-end processes across the organization.

The company partnered with LeverX to design and execute this PLM digital transformation. The solution focused on three key areas:

Seamless data migration to SAP PLM

LeverX used the VeloX migration tool to quickly and securely transfer all relevant equipment and specification data from EPIC and other legacy systems into SAP PLM. This approach reduced manual effort, minimized migration risk, and ensured data consistency in the new environment.

Standardization and automation of change management

Next, the LeverX team implemented the Integrated Process Solution (IPS) to automate change management workflows within SAP PLM. This enabled:

• Automated review and approval processes for materials, BOMs, and related documents
• Standardized, governed workflows across divisions and regions
• Improved traceability and compliance through clearly defined approval steps

Faster release to manufacturingLeverX customized engineering records and IPS-driven workflows so that all related objects move through approval phases in a controlled, transparent way. As a result, specification creation and change processes became faster and more reliable, enabling manufacturing to start sooner and with higher data quality.

Technology Stack

• PLM platform: SAP Product Lifecycle Management (SAP PLM)
  A central platform for managing product and specification data across the entire lifecycle. Provides a single source of truth for R&D, quality, regulatory, and manufacturing teams, independent of the ERP system.
• Process orchestration: IPS
  A LeverX solution for automating and governing change management workflows in SAP PLM. Supports standardized, auditable review and approval processes for materials, BOMs, and documents, enhancing collaboration across R&D, manufacturing, and quality.
• Data migration tool: VeloX
  A toolset used to accelerate and streamline the migration of equipment and specification data from the legacy EPIC PLM and other systems into SAP PLM, reducing manual work and improving data quality during the transition.

Results

By consolidating systems and automating PLM workflows with SAP PLM, IPS, and VeloX, the company achieved measurable, business-critical outcomes:

• Cycle times for specification creation decreased by more than 60%, allowing manufacturing to begin significantly sooner.
• Production capacity increased by over 25%, enabling the organization to handle more product changes and introductions with the same resources.
• A single source of truth for specification data was established, independent of the ERP system, providing greater supply chain leverage and visibility.
• Data quality and governance improved thanks to fewer systems, harmonized workflows, and end-to-end visibility across the product lifecycle.
• Compliance and quality risks were reduced through standardized, auditable processes and consistent specifications across regions and manufacturing sites.

The new PLM landscape has laid the foundation for a unified, efficient, and well-governed organization, ready to support further growth in the global hygiene and infection prevention market.