Faced with an over-engineered SAP proposal, this packaging manufacturer partnered with ABA to simplify, streamline, and unlock results—cutting logistics costs and accelerating go-live by 20%.

When a leading plastic packaging manufacturer evaluated SAP’s proposed system design for their supply chain transformation, it quickly became clear the solution wouldn’t deliver. The proposed design was too complex, too expensive, and misaligned with the business’s operational reality. Implementation timelines were unrealistic, and the projected ROI was underwhelming.

The client needed a smarter, more pragmatic approach—one that aligned with how their business actually worked.

The Challenge

The original SAP proposal failed on several fronts: it didn’t reflect existing workflows, exceeded acceptable cost and resource thresholds, and threatened business continuity during implementation. The supply chain team had limited flexibility within their outbound delivery model, and any significant disruption would have risked lost sales and escalating costs.

Key Constraints:

• An inflexible SAP template that didn’t match operational needs

• High expected cost and time to implement

• Risk of disruption from a one-size-fits-all design

Strategic Intervention

ABA Advisors, led by Sandy Torrekens and Abdul Maulud, stepped in to reframe the problem. Rather than force-fit a complex system, the team focused on redesigning the SAP solution around business priorities, pragmatism, and flexibility.

• Complete SAP Redesign: The system was rebuilt to align with the company’s real-world processes and constraints

• Simplified Architecture: Eliminated unnecessary complexity to enable smoother operations and faster deployment

• Flexible Outbound Delivery Models: Designed to work with existing practices, not against them

• Transport Optimisation: Internal transport flows were streamlined to improve efficiency across the network

Tangible Results

The new design delivered measurable gains across operations, logistics, and commercial performance:

• 35% Lower Distribution Costs

• 15% Reduction in Outbound Logistics Costs

• 5% Sales Growth

• 8% Reduction in Project Manpower

• 20% Shorter Project Timeline to Go-Live

These results proved that a well-aligned solution—rather than a standardised template—can deliver transformation with less risk, more agility, and stronger ROI.

Key Takeaways

This case demonstrates how ABA’s flexible, business-first approach to SAP design can unlock meaningful value. By simplifying the system and aligning it to operational realities, the client avoided unnecessary cost and disruption—while accelerating performance gains.

Without intervention, the business would have been locked into an expensive, complex system that couldn’t deliver the needed flexibility or return on investment.