SAP EWM-DM integration: MES-controlled staging
Integration between SAP Digital Manufacturing (DM) and SAP Extended Warehouse Management (EWM) using MES-controlled staging is crucial for agile and efficient production. This connection ensures that materials are delivered to the production line just-in-time, optimizes inventories, reduces errors and improves traceability. It also provides real-time transparency of inventory movements and production progress, aligns the warehouse with manufacturing requirements and supports the transition to smart factories.
MES-driven staging in SAP Extended Warehouse Management (SAP EWM)
When your SAP S/4HANA system is integrated with the Manufacturing Execution System (MES) SAP Digital Manufacturing (SAP DM), you can leverage MES-driven staging to create detailed plans that precisely fulfill the staging requirements of a production order.
Within SAP DM, these plans appear as staging requests, which are mapped in SAP EWM as stock transport orders for internal movements. A staging report in SAP EWM then evaluates the capacity of the Production Supply Area (PSA) and generates optimized warehouse tasks. These tasks can be structured and executed using advanced capabilities such as process-oriented storage control (POSC) or wave management.
Throughout the entire process, transparency is ensured in both systems. From planning to execution, you can monitor the status of staging activities, track requested quantities, materials in transit, and components already supplied, directly in SAP EWM or SAP DM.
The result: end-to-end visibility, greater efficiency, and a reliable material supply to production.
Overview of Staging Methods
When using Advanced Production Integration in combination with SAP Digital Manufacturing (DM) and SAP EWM, several staging methods are available:
- Cross-Order Staging
- Single-Order Staging
- Single-Order Staging with Warehouse Request
SAP EWM provides a checkbox to mark which staging methods are relevant for MES-driven staging.
Comparison of Staging Methods
Transferring Staging Methods to SAP Digital Manufacturing (SAP DM)
When a manufacturing order triggers staging in SAP S/4HANA, SAP EWM generates a Production Material Request (PMR). Each component in the PMR is assigned a staging method, which is then sent to the Manufacturing Execution System SAP Digital Manufacturing (SAP DM). SAP DM uses this information to create the corresponding staging requests for all required components.
The transfer is executed via SOAP messages, ensuring reliable communication between SAP EWM and SAP DM.
Creating Staging Requests in SAP Digital Manufacturing (SAP DM)
Staging requests are created in SAP DM using the Manage Staging 2.0 app. Only items with staging methods relevant for warehouse requests—such as Cross-Order and Single-Order with Warehouse Request—are displayed.
Steps to create a staging request:
- Select the required items in the app.
- Adjust quantities if necessary.
- Send the staging request to EWM.
EWM then generates a Stock Transfer Order, enabling advanced features such as wave management or process-oriented storage control (POSC) to manage complex scenarios efficiently.
Below, we show how wave management is used to execute the staging process:
Once the provisioning process in SAP EWM is complete, SOAP messages are sent to SAP DM to confirm provisioning and update inventory accordingly.
In addition, the status of each staging request can be monitored directly in the Manage Staging 2.0 app.
Technical Highlights
- MES-driven staging allows use of POSC, waves, and flexible warehouse task management
- End-to-end visibility from planning to execution
- Automated updates of stock status in SAP DM and SAP EWM
Inventory Management in SAP Digital Manufacturing (SAP DM)
After the staging process is complete, the inventory is synchronized with SAP DM and stored in the Manage Floor Stocks app displayed:
Cross order items: Inventory is consolidated in one line, without reference to a specific production order.
Single order items: Inventory is linked directly to the production order and the corresponding operation.
Conclusion
The integration of SAP DM and SAP EWM via MES-controlled staging provides manufacturers with a powerful framework to deliver materials to the production line exactly when they are needed.
In contrast to classic staging using standard PMRS, MES-controlled staging enables the use of advanced EWM functions, such as POSC, wave management and flexible warehouse task management, and supports complex scenarios with higher automation and efficiency.
The result: optimized warehouse and production processes, improved traceability, fewer errors and the necessary agility for Smart Factory.
FAQs
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MES-driven staging is a process where the Manufacturing Execution System (MES), such as SAP Digital Manufacturing, directly controls warehouse processes in SAP Extended Warehouse Management (EWM). The goal is to provide material just-in-time for production while ensuring full transparency of inventory, quantities, and delivery status.
SAP EWM supports three main staging methods for production supply. In Cross-Order Staging, materials are consolidated through warehouse requests and staged for multiple production orders. Single-Order Staging creates warehouse tasks directly from a specific Production Material Request (PMR). The Single-Order Staging with Warehouse Request method combines PMR and warehouse request, enabling more precise and flexible material provisioning.
SAP EWM automatically transfers the assigned staging method for each PMR item to the MES, such as SAP Digital Manufacturing, via SOAP messages. The MES then uses this information to generate the appropriate staging requests and ensure seamless integration between warehouse and production processes.
MES-driven staging with SAP EWM allows the use of advanced EWM functionalities such as Process-Oriented Storage Control (POSC) and Wave Management. This increases automation, provides greater flexibility in complex production scenarios, improves transparency and traceability of materials, and optimizes both warehouse and production logistics. Companies benefit from more efficient processes, reduced errors, and improved end-to-end supply chain visibility.
Yes, MES-driven staging in SAP EWM is scalable and suitable even for smaller production lines. Even simple manufacturing setups benefit from the automation, real-time transparency, and seamless warehouse-to-production integration that MES-driven staging provides.
Two applications are primarily used in SAP Digital Manufacturing and SAP EWM. The “Manage Staging 2.0” app is designed to create and edit staging requests, while the “Manage Floor Stocks” app provides an overview of production-related stock levels once staging has been completed.
Yes, the status of each staging request can be tracked both in SAP EWM and in the “Manage Staging 2.0” app. This gives companies complete visibility of material provisioning from planning through execution to final confirmation, ensuring transparency in production logistics.
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