Challenge
JLR’s existing process and IT landscape created several challenges that limited efficiency and scalability. Legacy systems were complex and highly customised, restricting flexibility and real-time visibility across manufacturing and logistics. Disconnected platforms and fragmented data across manufacturing, engineering, and suppliers led to siloed operations and inefficiencies. Additionally, migrating systems while production lines ran 24/7 increased Go-Live risk, while limited integration created gaps in compliance, traceability, and quality management.
Solutions
A unified, future-ready SAP S/4HANA ecosystem was implemented, built on a clean digital core and standardised global processes. Leveraging SAP’s Fit-to-Standard and Keep the Core Clean approach, the transformation minimized customizations while integrating PLM, MES, and external systems. This enabled real-time visibility across engineering, manufacturing, logistics, and the broader supply chain, supported by a scalable global manufacturing process template.
JLR’s Operational efficiency was enhanced through EWM for automated warehouse operations, TM for synchronized transportation planning, and PP+S for improved production accuracy, along with PM for plant maintenance. End-to-end processes across procurement, finance, quality, and order management were standardised. Innovations such as PLM BoM integration via PDMI and the 3-Order Concept (Production, Procurement, Delivery) enabled a seamless digital thread and synchronized execution, culminating in a first-time right Go-Live with zero disruption to live production.