Driving Manufacturing Agility with 70% Less QA Effort and 2X Faster SAP Releases

A Global Fortune 500 manufacturer leveraged Zyrix Test Autopilot to automate SAP QA at scale, accelerating S/4HANA digital core modernization and enabling agile, production-to-finance workflows across its global operations.

70 %

reduction in QA effort

2 X

faster SAP release cycles

60 %

fewer post-release defects

Client Background

A Global Manufacturing Powerhouse

Global Footprint

200+ plants in 45+ countries producing industrial, automotive, and consumer goods

SAP Core

SAP S/4HANA, ECC, and custom Z-modules powering production, inventory, and finance

Transformation Focus

Shift to smart factories, real-time supply chains, and IoT-enabled workflows

Strategic Move

Partnered with Zyrix to eliminate manual QA bottlenecks and scale SAP modernization

The Challenge

QA Bottlenecks in a High-Velocity Manufacturing

With S/4HANA upgrades and smart factory rollouts underway, manual SAP testing could no longer keep pace, delaying procurement, batch production, and audit readiness.

Manual Testing Fatigue

4–6 week regression cycles; QA effort tripled during patches

Complex Supply Chain Integrations

MES, WMS, SCM, PLM systems and custom Z-programs for batch tracking, BOM, and inventory logic

Limited Automation

Only ~40% workflows automated across critical paths like Procure-to-Pay and Make-to-Order

Compliance Risk

QA gaps exposed vulnerabilities in audit-critical workflows (GMP, batch release, traceability)

Zyrix Test Autopilot for SAP

Why Zyrix Was Chosen

Zyrix offered deep SAP manufacturing expertise, AI-driven test creation, and resilient automation across hybrid SAP landscapes.

Pre-built SAP Manufacturing Test Packs across MM, PP, SD, FI/CO, and Z-transactions

AI-led test generation using transactional and batch data

No-code test logic authoring for QA and plant operations teams

Implementation Journey: A Phased Rollout Across Manufacturing Functions

Phase 1 Discovery & Prioritization

Mapped high-risk flows across production, procurement, and finance.

Pilot Program Phase 2

Automated 60+ test cases across P2P and MRP processes in two plants

Phase 3 Global Expansion

Scaled automation across 15 countries, 200+ workflows,

Enablement & CI/CD Integration Phase 4

Trained 30 QA engineers and 20 production planners; embedded QA into SAP DevOps pipeline

Key Features Implemented

Automated Test Coverage

Procure-to-Pay:
Vendor onboarding, PO creation, GRN, invoice matching
Make-to-Order:
Sales order triggers, MRP runs, batch job validation
Inventory & Logistics:
Interplant transfers, warehouse pick/pack, cycle counts
Financial Closing:
Journal entries, depreciation, GR reconciliation, audit trails
Compliance & Audits:
Batch release validation, quality gates, serial traceability

Advanced Capabilities

SAP GUI + Fiori automation with no-code scripting
Data-driven tests using SKU, plant, vendor, and material master data
Parallel execution cutting test times by 80%
Dashboards aligned with SAP Solution Manager and Manufacturing Execution KPIs
CI/CD pipeline integration with SAP Cloud ALM and Jenkins

Results & Benefits

Quantitative Outcomes

2 X

faster regression cycles, cut from 30+ days to <10

90 %

increase in test coverage across SAP manufacturing modules

50 %

cost savings from test reuse across plants

Operational Benefits

100+ test cases reused across global sites
24/7 regression cycles during downtime
Zero defects in 3 consecutive S/4HANA rollouts

Team & Process Benefits

Shifted QA focus to exploratory, edge-case, and compliance testing
Empowered business and plant teams via no-code automation
Dev–QA collaboration enhanced with shift-left test practices

Business Impact

Accelerated deployment of smart factory initiatives
Reduced QA risks in regulated environments
Improved production continuity and plant readiness

Client Testimonial

A Partnership for Success

“Zyrix gave us QA that’s as lean and scalable as our production lines. We now deliver SAP rollouts and factory digitization in parallel with speed, confidence, and no fire drills.

VP, Global SAP Transformation,

Manufacturing Major

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