About the Customer
Our customer is a leading Indian multinational steel producer with operations in 26 countries and an annual crude steel capacity of over 30 million tonnes, ranking among the largest globally. They manage complex production facilities requiring frequent shutdowns and turnarounds.
Business Scenario
With SAP S/4HANA in place, the customer managed 400+ mini and 50+ major shutdowns yearly across their global steel production facilities. However, relying on multiple tools for planning, execution, and reporting led to inefficiencies and governance challenges.
Challenges
- Ensuring Proper Governance – Maintaining consistent oversight during STO planning and execution was challenging across multiple plants and countries without unified processes.
- Lack of Reliable Data – Inconsistent and untimely information led to unexpected project slowdowns, making it difficult to maintain production schedules.
- Critical Asset and Material Information Missing – Planning tools lacked visibility into asset availability and material status, causing delays and resource allocation issues during shutdowns.
- SAP System Had Minimal Insights – Limited visibility into plan and execution status within SAP prevented proactive management and real-time decision-making.
- Inability to Act Quickly – Untimely or untrustworthy data prevented rapid response to emerging issues during critical shutdown windows.
Solution
Built using Procify, our AI-powered low-code/no-code platform.
The customer selected Procify STO Manager, a comprehensive SAP-based STO management tool, for its ease of use and end-to-end capabilities, with mobile add-on for execution agility and customized workflows for unique requirements.
- End-to-End STO Management – Deployed single SAP-integrated solution covering scoping, planning, execution, and reporting, eliminating need for multiple disconnected tools across global operations.
- Mobile Add-On – Enabled agile execution with real-time data capture, updates, and field accessibility, allowing shutdown teams to work efficiently at plant locations.
- Customized Workflows – Developed customer-specific processes on top of the standard solution to align with internal governance requirements and steel industry best practices.
- Dynamic Scheduling and Gantt Chart – Replaced third-party scheduling tools with integrated SAP-based Gantt chart for better planning, tracking, and critical path management.
- Digital Documentation and Attachments – Centralized access to Standard Operating Procedures (SOPs), technical drawings, and equipment history for quick reference during shutdowns.
- Advanced Work Pack Management – Streamlined work pack creation, assignment, and tracking for internal teams and contractors across multiple shutdown activities.
Business Impact
- Single SAP-Based Platform – Unified solution ensured no duplication of data or processes across 400+ mini and 50+ major shutdowns annually.
- Real-Time SAP Insights – Complete visibility enabled proactive issue resolution and better decision-making during critical shutdown periods.
- Mobile Access Enabled – Field teams facilitated quick updates and task tracking directly from plant locations during shutdown execution.
- Clear Visibility Across All STO Phases – Enhanced governance through comprehensive tracking from planning through execution and closeout.
- Optimized Planning and Reduced Duration – Better coordination and resource visibility shortened shutdown timelines, minimizing production loss.
- Minimized Overruns – Improved budgeting and resource allocation reduced cost overruns and schedule delays.
- No Integrations Required – Fully developed within SAP S/4HANA, eliminating complex and costly external system integrations.
