Back To Case StudiesAutomation-Driven Operational Transformation for a Global Manufacturing Enterprise
Introduction
Manufacturing organizations often operate within complex ecosystems involving suppliers, production units, logistics, and customer networks. Manual processes and disconnected systems can slow production cycles, increase operational costs, and limit real-time visibility.
A leading global manufacturing enterprise partnered with Axia Kairos to implement an automation-first operational framework using SAP BTP and advanced testing methodologies. The goal was to enhance productivity, streamline workflows, and improve data accuracy across its multi-plant operations — enabling a smarter, faster, and more connected manufacturing process.
Business Challenge
The enterprise’s production and quality management systems were heavily dependent on manual data entry and batch-based reporting. This led to inefficiencies in process execution, high operational overhead, and delayed decision-making.
Key challenges included
Manual workflows across procurement, production, and dispatch stages.
Lack of real-time visibility into production KPIs.
Inconsistent testing and quality assurance processes.
High human dependency for repetitive system transactions.
Siloed systems without automated integration with SAP.
Solution Implemented
Axia Kairos led a comprehensive automation and SAP modernization initiative leveraging SAP Business Technology Platform (BTP), robotic process automation (RPA), and continuous testing frameworks
Workflow Automation
Automated procurement approvals, production tracking, and dispatch scheduling using SAP BTP’s workflow engine
RPA Implementation
Deployed bots for repetitive SAP transactions, reducing manual effort and error rates
Data Synchronization
Integrated IoT data from shop floors with SAP systems for live production insights
Testing Automation
Established a continuous testing pipeline ensuring stable releases and faster validation cycles
KPI Dashboards
Developed visual dashboards using SAP Analytics Cloud for production, quality, and operational metrics
Governance Framework
Designed role-based controls and process governance policies for long-term sustainability
Technologies & Services Used
SAP BTP (Business Technology Platform)
Robotic Process Automation (RPA)
SAP Datasphere
Testing Automation
Data Engineering & Analytics
Results & Impact
By adopting automation at scale, the manufacturer significantly improved production throughput, reduced costs, and established a connected digital backbone
Reduced Manual Operational Effort
Achieved a 55% reduction in manual workloads by automating repetitive operational tasks, freeing teams to focus on higher-value activitie
Faster Production Cycles
Enabled 35% faster production cycles through real-time operational visibility, allowing teams to identify bottlenecks and optimize processes instantly
Zero Critical Defects
Delivered zero critical defects post-deployment by implementing automated testing frameworks that improved accuracy, coverage, and release confidenc
Improved Cross-Functional Collaboration
Enhanced coordination between supply chain, production, and quality teams through integrated data flows and unified operational dashboards
More Accurate Production Forecasting
Leveraged data-driven insights and predictive analytics to improve forecasting accuracy by 10%, enabling better demand planning and inventory alignment
Stronger Operational Efficiency
Established an intelligent, connected production environment that supports continuous optimization, higher throughput, and scalable growth