To scale its global production capabilities amid rising market complexity, BorgWarner set out to transform its supply chain and production planning processes. Facing challenges with data accuracy, operational alignment, and underutilized SAP capabilities, the company partnered with Reveal to unlock the full potential of its SAP investment. Through Reveal’s Value Optimization® approach, BorgWarner achieved a 24% reduction in inventory, 92% drop in overdue demand and supply elements, and significant improvements in schedule attainment, visibility, and decision-making. The results delivered measurable, sustainable business outcomes aligned to BorgWarner’s strategic growth plan.

The Challenge

BorgWarner, a global leader in powertrain systems for both passenger and commercial vehicles, faced rising operational complexity driven by evolving market demands. Key business challenges included:

• Inconsistent alignment between performance targets and day-to-day operations
• Limited traceability and responsiveness due to fragmented MES and shop floor automation
• Inaccurate data and lack of user confidence in SAP
• Inadequate planning and production visibility to support business growth

The organization needed to unlock operational efficiency, improve decision-making, and ensure SAP served as a strategic business asset—not just a system of record.

The Decision

Recognizing that SAP had untapped potential to drive value, BorgWarner partnered with Reveal to close the gap between what SAP can do and how teams were using it. Reveal’s hands-on, business-first approach—focused on sustainable outcomes rather than one-time system fixes—aligned perfectly with BorgWarner’s long-term strategic goals.

{{customer-quote}}

The Transformation

Through Reveal’s Value Optimization® program, BorgWarner undertook a structured transformation across its supply chain and production operations:

• Optimized materials planning, procurement, and inventory management
• Deployed advanced SAP-driven production capacity, scheduling, and dispatching strategies
• Established a standardized business process framework with clear documentation and accountability
• Enabled end-to-end production planning to support growth and complexity at scale
• Empowered planners with SAP education, enhancing data accuracy and confidence in decision-making

This transformation was not about system configuration—it was about unlocking business performance hidden in existing processes and tools.

The Results

Financial Impact:

• 24% inventory reduction, freeing up working capital
• 28% reduction in dead stock
• 16% increase in stock turns

Operational Excellence:

• 84% reduction in negative Days of Supply
• 81% fewer exception messages
• 92% drop in overdue demand and supply elements
• Improved schedule attainment and production efficiency

Organizational Impact:

• Improved data accuracy and planning effectiveness
• Increased planner confidence and SAP utilization
• Enhanced visibility and analytics across the supply chain

Industry Recognition:

• SAP Automotive Excellence in Operational Performance Award (2018)
• Presidential Award for Turbo Project Excellence (2017)

By transforming how SAP supports its operations, BorgWarner proved that the right approach can unlock millions in hidden profit. Reveal’s Value Optimization® program helped turn SAP from a cost center into a competitive advantage—delivering lasting impact across production, planning, and supply chain performance.

Ready to unlock profit hidden in your operations? Let’s turn your SAP investment into measurable business outcomes.