BHP, the world’s largest diversified resources company, faced systemic disconnects between plant maintenance and supply chain operations, limiting their ability to optimize SAP and achieve reliable data insights. By partnering with Reveal and leveraging the oVo® methodology, BHP streamlined global maintenance and procurement processes, improved inventory accuracy, and dramatically reduced free-text purchases. The result: $4 million in cost avoidance across five countries, improved system trust, and sustainable operational performance.

The Challenge

Despite operating at a global scale, BHP struggled with fragmented processes and inconsistent SAP usage across its maintenance and supply chain functions.
Key issues included:

• Plant maintenance processes that operated outside SAP, reducing visibility and control.
• Inaccurate recording of purchasing decisions and parts movement, impairing traceability and reliability analysis.
• High volume of free-text purchases undermining sourcing strategies and automation.
• A disjointed repairable process without audit trail capabilities.
• Limited inventory accuracy, which diminished user confidence and led to costly workarounds.

These inefficiencies hampered BHP’s ability to implement proactive, data-driven decision-making and undermined global alignment across operations.

The Decision

To transform its global operations, BHP selected Reveal and its proven oVo® methodology. The company recognized the need for a strategic partner that could help unlock the full potential of SAP, integrate maintenance and supply chain workflows, and deliver measurable business outcomes—not just system configurations.

The Transformation

Reveal deployed its methodology across five global sites—USA, Trinidad, Pakistan, UK-North Wales, and Australia—initiating a comprehensive transformation. Key actions included:

• Educating cross-functional teams on SAP best practices for maintenance, planning, execution, and reporting.
• Enhancing collaboration between maintenance, supply chain, and production through Process Aligned Teams (PATs).
• Redesigning processes to manage by exception and integrate SAP across operational silos.
• Prioritizing data integrity and master data governance to support accurate, real-time decision-making.
• Establishing KPIs aligned with strategic goals and embedding them into a unified global dashboard.

The Results

BHP achieved measurable, strategic impact across its operations:

• $4 million in cost avoidance across five international sites.
• 99% on-time and accurate transactions within SAP, reducing reliance on manual oversight.
• 25% improvement in inventory accuracy, restoring confidence in SAP and curbing workarounds.
• 50% reduction in free-text purchases, streamlining procurement and enhancing compliance.
• A revised repairable process that now tracks progress and prompts actions within SAP.
• A standardized global dashboard to measure and manage operational performance consistently.

The Customer Voice:

“Reveal helped us turn SAP from a transactional tool into a strategic business asset. The improvements in inventory accuracy, auditability, and maintenance integration have delivered real financial impact across our global operations.”
— Global Operations Executive, BHP

BHP’s journey illustrates what’s possible when SAP is fully aligned with business processes, people are empowered to manage by exception, and data becomes a driver of performance. Reveal’s oVo® methodology didn’t just optimize systems—it unlocked millions in hidden profit and positioned BHP for scalable, sustainable growth.

Ready to close the gap between SAP’s potential and your reality? Let’s talk.

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