Transforming a global supply chain isn’t only about technology — it’s about rethinking processes, building resilience, and ensuring long-term scalability.
When a global automotive supplier with more than 1,500 employees set out to optimize its ERP LN kernel and redesign its EDI landscape, the challenge was clear: fragmented processes, manual workarounds, and outdated scheduling logic were limiting operational performance.
By introducing pull-based planning, scalable EDI integration, and a unified forecasting framework, the company has taken a decisive step toward supply chain excellence.
Project Highlights
- Company: Global automotive supplier (anonymous)
- Industry: Automotive supply & manufacturing
- Employees: 1,500+ worldwide
- ERP: Infor LN with ION middleware & EDI mapping layer
Key Challenges:
- Limited use of EDI in procurement and fulfillment
- High manual effort in shipping, invoicing, and order processing
- Forecast and planning inconsistencies across sites and suppliers
- No integrated pull planning logic in ERP LN kernel
From Push to Pull: Rethinking the Supply Chain Model
The company’s ERP LN implementation was originally designed around a push-based scheduling model to accelerate the go-live. But over time, this rigid setup clashed with business realities.
To align the ERP backbone with the company’s long-term supply chain strategy, the project team defined a new direction:
- Introduce pull-based planning logic via value streams and decoupling points
- Replace single purchase orders with purchase schedules and release management
- Build scalable EDI integration for internal and external suppliers
- Enable ASN-based (Advanced Shipping Notice) confirmations for automation in delivery and invoicing
- Establish a unified forecast and planning framework across the supply chain
Solution Design & Implementation
The solution was built on Infor LN with ION middleware and extended through advanced EDI capabilities. Key elements included:
- Modules Introduced: Purchase schedules (push & pull), ASN, Slim4 forecast integration, consignment-based fulfillment with multi-party invoicing
- Custom Enhancements: Pull logic embedded into ERP kernel, item-level forecast windows, surcharge logic for packaging & invoicing
- Integrations: Slim4 (long-term forecasting), Automotive Exchange Middleware (BOD ↔ EDIFACT mapping), Siemens portal (customer communication, later EDI)
Technical Breakthroughs:
- Designed mapping & processes for pull-based EDI
- Enabled ASN D97A messaging after shipment execution
- Standardized processes across internal and external suppliers
Project Execution
- Timeline: Q3 2023 – Q1 2024
- Team: Project management, ERP logistics & supply chain consultants, solution architect, IT business partners, and logistics stakeholders
- Key Milestones:
- Defined three core processes (Push Schedule, Pull Schedule, Single Order)
- Designed pull-based planning per value stream
- First external supplier onboarded with EDI integration
- Packaging surcharge process mapped and approved
Challenges & Actions:
- Supplier-specific requirements ➝ unified model introduced
- Limited forecast integration ➝ Slim4 item-level upload configured
- ERP kernel lacking pull logic ➝ initiated change request & design phase
Results & Business Value
Operational Improvements:
- Reduction of manual effort in procurement and shipping
- Automated forecast upload & structured planning windows
- More consistent supplier collaboration
Strategic Benefits:
- Faster responsiveness to market demand
- Transparent, unified planning across the value chain
- Improved data quality for decision-making
Stakeholder Voices:
- “Confirmed orders should drive fulfillment — not assumptions.”
- “Separating push and pull logic has transformed how we plan supply.”
- “We finally have a structure for aligning demand and system behavior.”
Lessons Learned & Best Practices
This project highlights important takeaways for manufacturers navigating complex ERP and supply chain transformations:
- Value stream–based decoupling is key for hybrid push/pull supply chains
- ERP kernel flexibility must be embedded from the start
- Forecast and demand should be decoupled at both process and system level
Recommendations for Future Projects:
- Evaluate forecast behavior early, at item level
- Tie pull logic directly to decoupling points within value streams
- Integrate EDI into the core design, not as an afterthought
Conclusion
By aligning technology, process, and strategy, this automotive supplier achieved more than just an ERP optimization — it established a foundation for scalable, demand-driven supply chain excellence.