SAEL Ltd
Integrated Planning That Powers Production Uptime
- Client: SAEL Ltd
- Industry: Renewable Energy – Solar, Biomass & PV Manufacturing
- Region: India
Summary
SAEL Limited is one of India’s fastest-growing renewable energy companies, managing solar plants, biomass facilities and a newly expanded PV module manufacturing division. As SAEL’s SAP partner, Orane delivered a scalable SAP S/4HANA Plant Code Rollout and comprehensive SAP-Managed Support (AMS), ensuring seamless expansion, process standardization, accurate costing, and continuous system reliability across all plants.
Key Results
- Successful SAP plant rollout across solar, biomass & PV module units
- Zero-disruption go-lives with standardized processes
- Full production planning setup for PV module manufacturing
- Improved inter-plant transfers, subcontracting & costing accuracy
- SLA-driven SAP-Managed Support ensuring continuous stability
Client Snapshot
Employees: Workforce across solar plants, biomass plants & PV module factory
Units Covered: Solar plants, biomass power facilities, PV module manufacturing
Solutions Delivered (Features):
- SAP Plant Code Rollout in S/4HANA
- Configuration of MM, FICO, PP, PM & Asset Accounting
- PV module manufacturing planning: BOMs, Routings, Work Centers
- Inter-plant STO & subcontracting automation
- Harmonized master data repository
- SAP-Managed Support (AMS):
- Incident & change request management
- Critical job/interface monitoring
- Transport & change control
- Performance tuning
- Month-end support
- Governance & quarterly improvements
Engagement Type: SAP S/4HANA Rollout + SAP-Managed Support
Implementation Duration: Multi-plant phased rollout and ongoing AMS
The Challenge
- Non-standardized plant operations with each new plant running its own version of procurement, production, and inventory processes, causing inconsistencies and errors.
• Weak production planning in PV module manufacturing, including absence of structured BOMs, routings, and cost frameworks, leading to inaccurate tracking and costing.
• Fragmented master data across materials, vendors, assets, and cost centers, resulting in errors in valuation, capitalization, and reporting.
• Inefficient logistics operations, such as delays in subcontracting, inter-plant stock transfers, and goods movement reconciliations.
• Operational delays in procurement and planning due to misaligned processes across plants and high reliance on manual interventions.
• Limited visibility into asset lifecycle and cost monitoring, affecting profitability and financial accuracy.
• Need for predictable, SLA-based SAP support to manage expanding operations and prevent system issues from affecting business continuity.
The Solution
- Standardized SAP plant configurations across all solar, biomass, and PV module units, ensuring consistent MM, FICO, PP, PM, and AA processes.
- Built complete PV module manufacturing capability with structured BOMs, routings, work centers, and master data extensions, enabling traceability and accurate production costing.
- Strengthened logistics operations by optimizing STO cycles, inter-plant transfers, subcontracting workflows, and goods movement checks.
- Executed master data harmonization to unify materials, assets, vendors, and cost-center structures across the enterprise.
- Established a full SAP AMS model, including SLA-driven ticket resolution, technical monitoring, job oversight, and month-end closing support.
- Introduced quarterly improvement cycles focusing on performance tuning, workflow enhancements, and business-requested optimizations.
Business Benefits
• Zero disruption during new plant rollouts due to standardized configurations and smooth transitions.
• Faster procurement and production cycles, reducing manual effort and improving plant readiness.
• Higher production efficiency in PV module units through structured planning and work-center scheduling.
• Accurate profitability and asset reporting enabled by correct capitalization, depreciation, and cost allocation.
• Improved inventory visibility & material traceability across all plants, reducing operational risk.
• Consistent compliance and reduced process errors via standardized workflows and harmonized master data.
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