Implementation Standards and Industry-Specific Adaptation of SAP-Lean Production Integration in Manufacturing: A Multi-Case Validation with Quantitative Performance Optimization

Qiang Fu
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Qiang Fu: WQKX (Wanqi Qianxiao), Beijing 100002, China

Frontiers in Management Science, 2025, vol. 4, issue 5, 67-74

Abstract: The decoupling between SAP systems and lean production (LP) has become a critical barrier to manufacturing digital transformation, leading to 15-22% overproduction rates, 20-30% delayed deliveries, and 12-18% cost wastage. To address this, this study proposes a systematic four-stage integration framework (Needs Quantification → System Configuration → Process Reengineering → Dynamic Evaluation) and industry-specific adaptation schemes for the automotive, electronics, and equipment manufacturing sectors. Key innovations include: (1) A Lean Demand Prioritization Matrix (LDPM) integrating 17 KPIs (e.g., production plan update frequency, material arrival tolerance) with AHP-based weight assignment, improving needs analysis accuracy by 32.7% vs. traditional interviews; (2) A Real-Time Lean Rule Embedding Engine (RTLREE) that embeds JIT, kanban, and TPM rules into SAP modules, achieving 99.2% rule execution accuracy—18.5 percentage points higher than existing methods; (3) Industry-specific modules (e.g., automotive BOM auto-switching, electronics rapid changeover) with 89.5% functional reuse rate. Validated across 32 manufacturing enterprises (16 experimental, 16 control) in China, Germany, and Japan over 18 months, the framework achieved: (1) Average overproduction rate reduction by 68.3% (from 15.2% to 4.8%, p

Keywords: SAP system; lean production; manufacturing digital transformation; integration framework; industry adaptation; real-time data synchronization; production efficiency; cost optimization (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:bdz:frmans:v:4:y:2025:i:5:p:67-74

DOI: 10.63593/FMS.2788-8592.2025.09.008

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