The Customer
Global CPG enterprise running SAP S/4HANA Cloud, private edition (RISE). Plant operations and supply-chain planning span multiple geographies, with thousands of materials flowing through MRP every week.
The Challenge
The customer had a large number of MRP-related support tickets where planners repeatedly had to suppress unnecessary Purchase Requisitions (PRs). Standard SAP MRP planned only against the primary BOM component and ignored available stock across alternate materials, creating constant procurement noise.
Every week, planners burned hours canceling PRs the system should never have generated. Because MRP is mission-critical, the noise spilled downstream into procurement, finance, and inventory — and the team still couldn't pinpoint the root cause after more than a month of internal investigation.
“Before Dodge AI, we knew several of our MRP processes were failing but couldn't pinpoint the root cause. Since MRP is mission-critical, the resulting procurement noise was costing our planners hours every day.”
Director of Supply Chain IT — $3B CPG Skincare Brand
How Dodge AI Helped
- Analyzed recurring MRP tickets and identified multiple bottlenecks related to alternate material planning.
- Proposed a targeted enhancement approach to enable priority-based alternate material consumption during the MRP run.
- Pinpointed the correct MRP Live enhancement point, guiding exactly where the implicit enhancement/BAdI logic should be implemented.
- Generated the BAdI enhancement logic and designed a Z-table configuration model to maintain alternate groups and priority order.
- Accounted for customer-specific material master fields used in their SAP instance and validated downstream planning impacts.
Impact
- 30% reduction in Procurement tickets after addressing the identified bottlenecks.
- 11 planner hours saved per week per plant previously spent suppressing PRs.
- 4× faster solution delivery — from more than a month of internal exploration to a working enhancement design within one week.
“Dodge AI quickly identified the bottlenecks and helped implement the right enhancement, leading to a 30% reduction in MRP-related support tickets and significantly less planning noise.”
Director of Supply Chain IT — $3B CPG Skincare Brand
