Greenfield S/4HANA Implementations
To expand its global presence, Magna International has established several new production plants
in Europe and North Africa in recent years. These facilities were not only built physically but also
equipped with modern digital infrastructure.
Magna opted for a consistent Greenfield strategy: the complete rebuild of SAP S/4HANA systems
ensured that each plant operated from day one on globally standardized, future-proof processes –
from Finance and Controlling to Logistics, Production, Supply Chain, and Quality Management.
Initial Situation and Challenges
The simultaneous commissioning of multiple production sites posed a dual challenge for Magna: while the plants were still under construction, the complete digital infrastructure had to be developed in parallel. Each location required a brand-new SAP S/4HANA system – covering Finance, Controlling, Production, Logistics, Supply Chain, and Quality Management.
Particularly demanding was the tight integration with industry-specific processes: Just-in-Time and Just-in-Sequence production, self-billing, advanced production supply, and seamless integration with MES, EDI, and barcode scanners. Every process, interface, and master data record had to be newly set up, tested, and stabilized – under tight deadlines and with the highest precision.
Approach and Implementation
msg Plaut introduced a structured Greenfield rollout methodology based on Fit-to-Standard template design. Global standards were defined while allowing room for local adaptations to meet specific market requirements.
Data was migrated from non-SAP or newly created sources, and core modules such as Finance, Controlling, Procurement, Production, and Logistics were implemented and seamlessly integrated with MES, scanner solutions, and EDI networks. msg Plaut was responsible for end-toend execution: from blueprinting and code adjustments to testing, training, cutover management, and hypercare support.
A key success factor was the close coordination with the physical plant construction. msg Plaut’s governance model and reusable rollout playbooks ensured consistency and speed across countries and divisions, despite parallel project streams.
"With msg Plaut, we were able to quickly and reliably establish new Magna plants on SAP S/4HANA. From
Finance and Logistics to Production and MES integration, msg Plaut ensured our Greenfield projects went
live on schedule in multiple countries – creating a solid digital foundation for our growth.“
Zdenek Vavra, SAP Program Manager, Magna International
Results and Added Value
The Greenfield implementations enabled Magna to smoothly and on schedule commission new plants in Europe and North Africa – equipped with a robust digital foundation that ensures efficiency and transparency from the outset.
The results are clear: a standardized global ERP core ensures consistency across divisions and regions. Real-time production visibility through integrated MES and scanner solutions increases transparency on the shop floor. Financial processes run on harmonized structures, and supply chain and logistics processes seamlessly support JIT/JIS operations and automated material flows.
Above all, Magna significantly reduced time-to-value through the combination of global templates with local execution – and was able to ramp up production capacity immediately after go-live.
References – Magna Greenfield Implementations
- Magna Exteriors Sunderland (UK) – Full SAP implementation for a new Greenfield plant (2019–2021, 22 months)
- Magna Exteriors Sybex (UK) – SAP R/3 implementation (2021–2022, 15 months with interruptions)
- Magna Exteriors Sybex (UK) – SAP R/3 implementation replacing legacy systems in a new production plant (2021–2022, 22 months)
- Magna Motrol Livorno (Italy) – Replacement of non-SAP system XPPS with SAP ERP, covering Finance, Production, and Logistics (2023–2024, 17 months with 7-month interruption)
- Magna Lighting Ostrava (Czech Republic) – SAP implementation for the Lighting Group Office, setup of Finance and Project Systems (2020–2021, 5 months)
- Magna Seating Tanger (Morocco) – S/4HANA implementation for a new Greenfield plant, rolled out based on the Vigo template (2023–2024, 12 months)
- Magna Mirrors Kenitra (Morocco) – SAP R/3 implementation for a new plant, including Finance, Production, and EDI (2019–2020, 10 months)
- Magna Seating Aleksinac (Serbia) – SAP R/3 implementation for a new Greenfield plant (2019–2020, 5 months)
- Magna Seating Vigo (Spain) – SAP implementation replacing multiple legacy systems in a large production plant (2022–2023, 14 months)
- Magna Seating Neuenstadt (Germany) – SAP implementation for a new seating plant, with strong focus on JIT processes (2021–2022, 13 months)
- Magna Powertrain Bordeaux (France) – SAP R/3 implementation (2021–2022, 15 months)
Conclusion
Greenfield implementations are more than technical projects – they are the key lever to equip new plants with robust, efficient processes and secure growth from day one. msg Plaut has demonstrated how speed, precision, and structured governance can digitally establish new production sites in record time.
The Greenfield projects complement Magna’s conversion programs and highlight the dual transformation strategy: modernizing existing plants and building new ones with best-in-class processes. With msg Plaut as a partner, both are achievable – securing Magna a scalable, future-ready platform for global growth.