Precision, performance, production: Seamless SAP S/4HANA migration at BMW Group

The BMW Group

SNP drives successful SAP S/4HANA rollout at BMW Group Plant Regensburg

BMW Group’s Regensburg plant proved that even the most complex SAP migrations can go live smoothly, on time, and without disruption. The result: uninterrupted production, higher output than expected, and a scalable blueprint for future rollouts.

BMW museum BMW museum

As part of its global transformation strategy, the BMW Group implemented the program "Prozesskette Teile (PKT)” aimed at harmonizing logistics processes and transitioning from SAP ECC to SAP S/4HANA for its plant in Regensburg. SNP played a key role in the project by enabling a complex and time-critical transformation. Leveraging Kyano CrystalBridge® and more than 150 customized Validate reports, SNP helped to ensure data integrity, reduce downtime, and support a smooth transition while maintaining production operations. This successful project serves as a reference for future rollouts.

The result was a smooth go-live completed on time, a higher vehicle output than expected during the ramp-up phase, and a scalable process architecture ready for global deployment. This project proves that even the most complex SAP migrations can be completed on time and without disruption – when collaboration, precision, and innovation align.

 

The challenge: transforming complexity into scalable innovation

 

In response to SAP’s technology shift and the phase-out of SAP ECC, SNP supported the PKT program – a strategic initiative to standardize logistics processes and reduce system complexity. With its extensive experience in complex transformation projects, SNP enabled a future-ready SAP S/4HANA landscape for one of the world's leading automotive manufacturers. The critical go-live required maximum precision and reliability – expectations SNP met with tailored tools, proven methodology, and a deep understanding of production-critical systems.

The stakes are high

 

  • Successful transformation implemented at BMW Group Plant in Regensburg
  • New logistics and warehouse processes live for several thousand employees
  • Fixed go-live window with zero tolerance for delays or disruptions

Key challenges

 

  • Transition from ECC to SAP S/4HANA within strict time and budget constraints
  • Avoidance of production downtime (“lost units”)
  • High expectations for test migration quality and data integrity
  • Business-critical risk of impacting ongoing production schedules

The solution: tailored tools, proven processes, trusted partnership

 

SNP supported BMW Group with its transformation solution Kyano CrystalBridge, using:

  • Migration Cockpit (MC) for a precise data migration
  • Kyano Validate for automated test validations and reporting

SNP developed over 150 custom Validate reports tailored to BMW Group’s specific needs, continuously refining them through multiple test cycles. This significantly increased transparency and reduced manual efforts. Drawing on classic project management, a joint cutover plan and close collaboration across Finance, Logistics and EWM, SNP ensured fast responses to change requests through modular Validate logic. This approach enabled a reliable and flexible migration process, even in the sensitive EWM area.

 

The result: fast ramp-up, full control, real business value

 

The SAP S/4HANA migration at BMW Group Plant Regensburg was completed on time during the yearly production pause, ensuring a smooth go-live and simultaneous maintenance work on critical machinery. Downtime was reduced from 60 to just 45 hours, allowing for a faster ramp-up and an even higher vehicle output during the start-up phase than planned. Beyond operational success, the project created a scalable, harmonized process landscape ready for global rollout.

The project: structured execution meets unrivaled precision

 

The PKT migration program was not just a technical upgrade, but a highly coordinated enterprise initiative. By aligning IT execution with operational priorities, SNP created a shared roadmap with clear milestones, strict governance, and transparent task tracking together with BMW Group. The result was a seamless transition from SAP ECC to SAP S/4HANA at the Regensburg plant, which was the first high-volume plant in Germany moving successfully to digital production logistics.

 

The partnership: trust, expertise, and alignment

 

SNP and BMW Group maintained trust, clear roles, and open communication, focusing on production  continuity and data integrity. SNP’s expertise and proactive approach ensured a smooth alignment based on regular meetings and a joint cutover plan. This strong partnership enabled BMW Group to successfully manage a complex migration with full transparency and control.

The SNP advantage

 

  • Transparency & decision-making

150+ custom Validate reports enhanced transparency and traceability, enabling faster decisions and efficient issue resolution across teams.

  • Data quality & operational reliability

Clean, validated data across Finance, Logistics, and EWM ensured operational reliability and minimized downstream errors, especially in the sensitive EWM area.

  • Fast testing & adaptation

Automated validation and modular logic reduced manual testing efforts and accelerated change validations. Fast response to change requests enabled a reliable and flexible migration process.

  • Downtime reduction

Cutover completed in 45h (instead of 60h), enabling faster production ramp-up.

Key lessons learned

 

  • Automated validation is critical

The intensive use of Kyano Validate revealed the need for further automation to reduce manual efforts during repetitive test phases.

  • Flexibility is a must

Requirements evolved after each test cycle. A modular validation logic was key to quick adjustments and quality assurance.

  • Joint planning drives control

A shared cutover plan provided structure and clarity, allowing both teams to coordinate detailed activities across technical and business layers.

  • Communication equals confidence

Transparent updates between SNP and BMW Group increased trust and enabled quicker decisions in high-pressure situations.

Key facts

  • Project Type_icon_white.svg

    Project type

    SAP S/4HANA migration

  • data_icon_white.svg

    System and modules

    1 legal entity, 1 production site; PP, PM, QM, SD, MM, FI, CO, EWM

  • downtime_white.svg

    Downtime

    Planned: 60h / Actual: 45h

  • info_icon_white.svg

    Solutions

    SAP S/4HANA, Kyano CrystalBridge® – MC & Validate

  • calendar_white.svg

    Duration

    April ‘23 – January ‘25

  • bulb_icon_white.svg

    Data volume

    1.53 billion records

Managing a transformation of this scale and complexity demands reliability, precision and comprehensive expertise. At the Regensburg plant, SNP assumed full responsibility – from planning to execution – enabling a go-live without disrupting production. Our tailored validation approach combined with close collaboration on-site ensured that the migration was completed on time and within budget. For us, this project sets a benchmark for future production-critical transformations.

Stefan Settele

Manager Project Management at SNP Group

About the BMW Group

With its four brands, BMW, MINI, Rolls-Royce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial services. The BMW Group production network comprises over 30 production sites worldwide; the company has a global sales network in more than 140 countries.

pin.svg

Headquarters

Munich, Germany

people.svg

Employees

159,104

building-three.svg

Industry

Automotive

line-chart.svg

Revenue

€142.4 bn in 2024