PreZero faced the challenge of phasing out its existing maintenance system and transitioning to SAP. The old system no longer provided the right support, making change necessary. After a period of preparation, the collaboration with Perfact started in April. The goal: to fully implement SAP PM for maintenance and other supporting processes at the Roosendaal site.
Bringing Structure and Insight
The Perfact project team consisted of Wim Vermeire, Lean Black Belt specialist with a passion for data and Project Leader in this setup, together with his colleagues Ian Boesten, Lean Consultant, and Jasper Sengers, Data Specialist and Maintenance Engineer. In close cooperation with PreZero’s project team, a structured plan was drawn up. This included a clear timeline, preparatory tests and training, and an inventory of what was already in place and what was still missing. This resulted in a concrete action plan that provided direction for all subsequent steps.
An important part was the Gemba Walk. “With a Gemba Walk, you literally go onto the shop floor to observe how employees carry out their work and what data they use. This gives a clear insight into which data is important and how it is applied. It sharpened our view on what was needed to properly configure the SAP system,” Wim explains. In addition, it not only provided insights into the quality of existing data, but also highlighted where the gaps were and which improvements needed to be made. “It was also an opportunity not just to transfer processes as they were, but to immediately redesign them in a leaner and smarter way,” Wim continues.
The findings were discussed with the IT department, which managed the implementation step by step. A key principle: PreZero employees should not be burdened with extra work or disruptions. Everyone had to be able to continue their daily tasks as usual.
Cleaning Data and Training People
A crucial step was data migration. Together with Wim Vermeire, Jasper Sengers took the lead in the data cleanup. “By applying standardization and cleaning the data, we brought the quality of the data to a higher level,” says Jasper.
In parallel, Ian Boesten developed a UAT (User Acceptance Test) and training program. With documentation and a training library, employees were gradually familiarized with SAP. This made the transition smoother and also laid the foundation for future use.
Stronger Together Through Flexibility
The collaboration went smoothly and was characterized by flexibility. Although no ready-made scripts or templates were available, much could be built from experience. Wim Vermeire played a key role in data quality and the operational side, while Ian further developed the UAT and training program.
According to Frank Gierman, SAP Specialist at PreZero, this teamwork was decisive: “It wasn’t always easy, but we always found a solution. The team’s flexibility, the willingness to go the extra mile, and the direct communication ensured that we were able to go live within the set timeframe.”
From Go-Live to the Future
At the end of August, the project was formally completed. The original scope—successfully migrating data, setting up new work processes, and training users—was achieved within schedule and planning. This now provides a solid foundation for further expansion of SAP.
“One of the developments still ahead is the integration of the procurement module, which is the next project on the agenda. However, we are deliberately taking our time with that, so that users can first get used to this transition before another change is introduced,” Frank explains. The foundation is solid, and the transition went smoothly. With this project, PreZero has gained more structure and a more future-proof data management system.
“One of these upcoming developments is linking the procurement module. This will be a significant efficiency gain. The requirements are currently being worked out in detail,” Frank adds. The foundation is solid, and the transition went smoothly. With this project, more structure has been created—and a more future-proof data management system.
