SAP Digital Manufacturing (SAP DM)
The future of MES is in the cloud – and on the shop floor. We are the only SAP DM consulting firm that also specializes in production planning, combining IT excellence with real-world manufacturing expertise to deliver a transformation that truly works.
Key Points at a Glance:
Challenge: SAP ME and MII is approaching end of support (2027/2030). Outdated on-premise MES systems hinder scalability, transparency, and Industry 4.0 initiatives.
Solution: Migration to and implementation of SAP Digital Manufacturing (DM) – SAP’s cloud-based standard MES solution with native S/4HANA integration and quarterly innovation cycles.
Result: Complete real-time transparency from ERP right down to machine level. Paperless manufacturing, automated traceability, and Lean 4.0-capable production.
io benefits: We are much more than just an IT firm. We have a deep understanding of shop floor realities from 40 years of factory planning – and configure SAP DM so that it truly supports your people and processes.
MES in the cloud: The SAP DM transformation
SAP Digital Manufacturing (SAP DM) is SAP’s cloud-based answer to outdated on-premises MES systems such as ME and MII. It is a SaaS solution, seamlessly connecting production control (resources, orders, worker guidance) with S/4HANA and SAP EWM. Integration on the Business Technology Platform (BTP) enables automated machine connectivity, AI-powered analytics, and quarterly software innovations – with no time-consuming server maintenance needed. io guide you through the entire SAP DM journey: from the initial fit-gap analysis through pilot implementation to global plant rollout.
Standardization and digitization of production processes across all plants.
Real-time shop floor connection (IoT/Edge) to S/4HANA or ECC for seamless OEE tracking.
SAP EWM integration and machine integration
Core Functions in Digital Manufacturing
Execution ×
Cloud-based production control system for detailed order planning and control as well as specific execution of the respective production processes
- Centralized production control system
- Dashboards for production employees
- Traceability
- Machine connectivity
Resource orchestration ×
Detailed planning tool for fine-tuning resources (employees, tools, etc.) at shop-floor level
- Scheduling and monitoring
- Human resource planning
- Comprehensive overview of current status of production orders, employees, workstations, machines and tools
Insights ×
Performance management solution that visualizes, analyses and evaluates large volumes of operating data in real time
- Production data analysis
- Based on raw data from production previously recorded by DMe
- Real-time production processes monitoring
- Flexible analysis and subsequent optimization of production processes at various levels (e.g. plant, production line, workstation and resources)
How we work
We combine SAP Activate and our agile project methodology to help you successfully implement SAP DM.
Discover
We research potential systems and product solutions taking your existing system architecture into account. We analyze your existing MES landscape, identify gaps, and define the strategic framework for your SAP DM implementation.
Prepare
We set up and prepare the project for subsequent phases. We establish the project organization, define roles and responsibilities, set up the system environment, and coordinate the project approach with your team.
Explore
We determine the project scope based on a gap analysis to assess coverage with standard or best-practice processes. We test scenarios in the system, identify customization needs, and coordinate user stories with the business units.
Realize
We apply user stories to define the detailed implementation scopes, which are then realized in sprints before testing and handing over to the user. Our agile approach ensures that you can see and verify results early on in the process.
Deploy
The implemented solution is deployed to the production environment. Migration and cutover activities are carried out, end users are trained, and the go-live is carefully prepared – with minimal operational risk.
Run
After go-live and subsequent ramp-up support (hypercare), we complete the transition to operational mode. Our 24/7 support is available – for a robust, scalable, and continuously improved SAP DM environment.
Comprehensive SAP DM expertise
We are production specialists, covering the entire lifecycle of the digital manufacturing solution – from IT strategy to machine connectivity.
SAP DM - Strategy & consulting
SAP DM strategy & consulting
The path to the cloud
We analyze your MES architecture and develop a roadmap for the transition to cloud-based SAP DM.
SAP DM - Implementation
SAP DM implementation
From template to rollout
Configuration, customization, and company-wide rollout of SAP DM. Tailored to your production needs.
SAP DM – Migration: SAP ME / MII to SAP DM
Migration: SAP ME / MII to DM
Future-proof migration
Secure data and process migration from on-premises solutions (SAP ME / MII) to the cloud architecture.
SAP DM - Shop floor integration
Shop floor integration
Machine connectivity (IoT)
We connect PLCs and machine controls directly to SAP DM via PCo / Plant Connectivity for real-time data.
SAP DM for discrete industries
SAP DM for discrete industries
Focus on discrete manufacturing
Assemblies, assembly, and traceability. Specific best practices for mechanical engineering and the automotive industry.
SAP DM for process industries
SAP DM for process industries
Focus on process industries
Recipes, batch traceability, and weighing systems. Optimized for the pharmaceutical, chemical, and food industries.
Our Services for Implementing SAP Digital Manufacturing
We provide tailored service bundles for every phase of your SAP Digital Manufacturing (SAP DM) initiative – from strategic alignment and validation to system migration. Whether you need a Discovery Workshop, a Proof of Concept, or support in migrating from SAP ME/MII to SAP Digital Manufacturing –
Here, you'll find structured service packages with clear objectives and measurable results:
Orientation & Strategy
Discover Day ×
Objective
The purpose of the Discover Day is to provide a compact overview of SAP DM with theoretical input, system insights and a focused deep dive.
Contents
- Introduction to SAP Digital Manufacturing
- Hands-on live demo in the system
- Overview of SAP DM functions
- Deep dive on prioritized topic (e.g. quality, analytics, execution,...)
- Derivation of required steps for an SAP DM implementation
- Factory tour & evaluation of actual processes
Deliverables
- Documentation of the key findings & conclusions
- Recommendations for further steps with SAP DM
Key Facts
Duration
1 day
Target Group
- Companies interested in SAP DM
- Project teams in S/4HANA implementations
- Departments in production e.g. production planning and maintenance
- IT
Format
- On-site
- Combination of presentation, live demo, factory tour & workshop
Lean 4.0 & Operational Excellence ×
Objective
The purpose is to develop a roadmap for the introduction of Lean 4.0 with SAP DM in order to achieve operational excellence through digital technologies.
Contents
- Introduction to Lean 4.0 and SAP DM, linking lean principles with digital tools
- Digital value stream mapping with pain points clustering & target image
- Use cases such as digital value stream mapping, 5S audits and trend analyses, E-Kanban & warehouse control, predictive maintenance
- Development of an individual implementation strategy
- Leadership & change management in digital transformation
Deliverables
- Practice-oriented use cases & best practices
- Rough concept of a roadmap for the introduction of SAP DM
- Recommendations for leadership, change & integration
- ROI and KPI estimation for pilot phase
Key Facts
Duration
3 days
Target Group
- Plant & Operations Manager
- Head of Production / Operational Excellence
- Digital Manufacturing / Industry 4.0 Program Manager
- IT/OT Architects
Format
- On-site and remote
- Theory & live demos
- Analysis & workshop
- Interactive discussion & Q&A
Industry 4.0 & SAP DM ×
Objective
The purpose is to convey a strategic approach to digital transformation in manufacturing, with a particular focus on how SAP Digital Manufacturing can be embedded in a future-oriented Industry 4.0 roadmap.
Contents
- Overview of SAP Digital Manufacturing in the context of Industry 4.0
- Best practices from the digital transformation of production
- Identification and evaluation of relevant smart factory use cases with SAP DM and other technical solutions
- Discussion of organizational, process and IT-related changes
- Presentation and implementation of the end-to-end process for creating an Industry 4.0 roadmap
Deliverables
- Initial structure for a digitalization roadmap (short-, medium-, long-term measures)
- Evaluation and prioritization of specific SAP DM and smart factory use cases
- Recommendations for action and next steps for implementation
Key Facts
Duration
2 days
Target Group
- Head of production
- IT/OT managers
- Digitization representatives
- Process and lean managers
Format
- On-site or remote
- Theory & live demos
- Interactive discussion & Q&A
Feasibility Assessment & Pilot
Master Data Readiness Check ×
Objective
The goal is to support companies early on, ideally before an SAP DM project or during an S/4HANA transformation, in the analysis and preparation of their relevant master and transactional data.
Contents
- Introduction and application of the "Master Data Cookbook“
- Identification of affected processes and relevant data sources
- Analysis of the actual state and assessment of data quality
- Consulting on consolidation, supplementation, and cleansing of relevant master data
- Test runs for validation and ensuring system compatibility
- Derivation of an action plan for sustainable data maintenance
- Identification of data gaps to enable additional SAP DM functionalities
Deliverables
- Detailed analysis report with relevant master data structures
- Cleansed and enriched data for SAP DM
- Test protocols and validation reports
- Action plan and toolset for continuous data maintenance
Key Facts
Duration
10 days
Target Group
- Master data managers
- Production planning / work preparation
- IT / ERP teams
Format
- A mix of workshops, data analysis, and remote sessions.
Lighthouse / MVP Implementation ×
Objective
The goal is to implement SAP DM quickly and focused within a defined pilot area in order to validate the solution and make it operational with a productive go-live.
Contents
- Kick-off & preparation workshop including current state analysis of the end-to-end order process and shop floor tour
- Integration with SAP ERP and execution of initial tests
- Conducting explore workshops (focus: execution & quality) with prioritization of work packages
- Configuration and unit testing of pilot functions
- Integration testing, cut-over preparation, and deployment in the production system
- Go-live of the pilot area including hypercare phase and optional functional expansion
Deliverables
- Configured SAP DM system for the pilot area
- Training of key users and supported go-live
- Roadmap and recommendations for further rollout/extensions
Key Facts:
Duration
3 months
Target Group
- Production Management
- Key Users (Production, Quality, IT)
- SAP Integration Team
- Project Management (Customer & Partner)
- Shopfloor Supervisors
Format
- Combination of on-site and remote workshops
- System configuration, testing, and training
Discover Project & Proof of Concept (Large) ×
Objective
The goal is to implement a realistic PoC scenario beyond the scope of the Small Package, including ERP and machine integration, with a conclusive, well-founded assessment of costs, schedule, and subsequent steps.
Contents
- Shop floor tour & end-to-end process assessment
- SAP DM basics training & deep dive into core SAP DM functions
- Definition of the PoC scenario including data provisioning
- Proof of Concept including ERP and machine integration in the customer system
- Analysis and integration of SAP DM into the existing IT/OT architecture
- Identification of relevant use cases & derivation of a business case
Deliverables
- Documentation of results and analyses
- Complete PoC including real system integration (ERP & machines)
- Management summary with recommendations for action
- Proposal for further project approach (including high-level cost indication and roadmap)
Key Facts
Duration
>10 weeks
Target Group
- Business and process owners
- Digitalization officers
- IT leads, SAP architects, in-house experts
- Project managers and decision-makers
Format
- On-site or remote
- Interactive workshops with presentations, demos and discussions
Discover Project & Proof of Concept (Small) ×
Objective
The goal is to analyze the current situation, provide basic knowledge of SAP DM, and generate concrete insights and recommendations for further steps through a proof of concept.
Contents
- Shop floor tour & end-to-end process assessment
- SAP DM basics training
- Deep dive into core SAP DM functions
- Definition of a suitable project approach (e.g. template-based)
- Execution of a proof of concept in io’s SAP DM system (without ERP and machine integration)
Deliverables
- Documentation of results and analyses
- Proof of Concept incl. use case(s)
- Management summary with recommendations for action
- Proposal for further project steps (incl. high-level roadmap)
Key Facts
Duration
4-6 weeks
Target Group
- Business and process owners
- Digitalization officers
- IT leads, SAP architects, in-house experts
- Project managers and decision-makers
Format
- On-site or remote
- Interactive workshops with presentations, demos and discussions
Transformation & Migration
Migration Readiness: SAP ME/MII to SAP DM ×
Objective
The goal is to systematically evaluate the existing SAP ME/MII solution, identify migration opportunities to SAP DM, and derive concrete recommendations for the transition.
Contents
- Analysis and evaluation of current and future processes and requirements
- Consideration of future business goals and priorities
- Assessment of the current ME/MII implementation regarding its suitability and alignment with SAP DM
- Risk assessment and recommendation of a migration path to SAP DM
- Detailed examination of business processes in their various forms
- Definition and prioritization of work packages
Deliverables
- Fit-to-standard analysis (including gap list)
- Overview and prioritization of relevant work packages
- Transformation roadmap with next steps
Key Facts
Duration
2 weeks
Target Group
- SAP ME/MII customers
- MES managers
- Digitalization managers
- Department heads & process owners
- IT leads, SAP architects, in-house experts
Format
- On-site or remote
- Interactive workshops with presentations, demos and discussions
Machine Integration Concept ×
Objective
The goal is to provide an overview of integration possibilities between the shop floor and SAP Digital Manufacturing, including architecture and machine connectivity.
Contents
- Assessment of the current machine connectivity
- Options for connecting machines to SAP DM
- Overview of connectivity models and integration strategies
- Presentation of typical production use cases with live demo
- Introduction to automation with SAP DM
- Fundamentals of fail-safety and data availability
- Discussion on technical feasibility and next steps
Deliverables
- Configuration guide with recommended actions
- Target architecture for machine integration
- Overview of supported business processes (status, data collection, alerts)
- Possible next steps for PoC or rollout
Key Facts
Duration
2 - 4 weeks
Target Group
- OT/IT architects
- Manufacturing and process owners
- MES, automation, and digitalization teams
Format
- On-site or remote
- Combination of technical demos, use case reviews, and discussions
Target Architecture & Integration Concept ×
Objective
The goal is to provide a comprehensive understanding of the technical architecture of SAP Digital Manufacturing as well as the integration mechanisms with SAP ERP and SAP EWM.
Contents
- Assessment of the current architecture
- Overview of the architecture and components of SAP DM
- Integration of SAP DM into existing ERP landscapes
- Connectivity to SAP EWM to support logistics processes
- Introduction to integration concepts and technical prerequisites
- Overview of security and communication structures
- Discussion of typical challenges and solution approaches
Deliverables
- Workshop documentation with architectural diagrams and recommendations
- Overview of possible integration scenarios (including technical options)
- Recommendations for the system landscape
Key Facts
Duration
3 weeks
Target Group
- IT architects and system owners
- Project managers in digitalization & ERP projects
- IT managers responsible for production systems
- Optional: OT managers
Format
- On-site or remote
- Interactive discussion on integration options and best practices
More
SAP DM-Booklet
Find out more about SAP DM, the benefits and our proof of concept packages in our SAP Digital Manufacturing booklet.
Why SAP DM with io?
Not only standardized
Customized SAP DM strategy
Every SAP DM implementation begins with an analysis of your production processes and system landscape. We develop a tailor-made target architecture and roadmap – tailored to plants, products, and integrations.
Scalable and
proven
SAP DM implementation
Experience from numerous SAP DM implementations – from pilot to global rollout. We create standardized, reusable solutions using template-based approaches, maintaining flexibility.
Seamless
processes
SAP integration
Integration of SAP DM into your system landscape – from S/4HANA through SAP EWM to the shop floor. For stable interfaces and seamless data flows along the entire process chain.
Planning meets execution
Shop floor & factory planning
Experience in factory planning and the design of real-world production processes. We approach SAP DM from the shop floor perspective – from layout and material flow to system-level implementation.
FAQ
What is the difference between SAP ME/MII and SAP DM? ×
SAP ME and MII are on-premise systems whose support is set to expire in the near future (depending on the version, 2027 or 2030). SAP DM is the modern, cloud-based SaaS successor solution that receives new features quarterly, requires no on-premise IT infrastructure, and integrates natively with S/4HANA.
What does SAP DM mean for Lean 4.0 and operational excellence? ×
SAP DM makes Lean principles digitally measurable. Waste (e.g., wait times, scrap) becomes visible in real time, OEE values are calculated automatically, and continuous improvement processes (CIP) are driven by data – with no paper-based manual evaluations.
We have a very old machine estate. Can it be connected to SAP DM? ×
Yes. We can also connect older control systems, retrofit sensors, and push the data to the cloud by using Edge components (SAP Digital Manufacturing for Edge computing) and protocols such as OPC UA.
Do we have to switch to S/4HANA before implementing DM? ×
No, not necessarily. SAP DM can also be integrated with an existing SAP ECC system. However, a strategic assessment in the context of an S/4HANA transformation makes perfect sense, which we evaluate during the roadmap phase.
Your expert for SAP Digital Manufacturing
In 30 minutes, we’ll work together to determine which area of focus offers the greatest impact for your current situation - and whether a structured pilot approach makes sense for you.
