Thyssenkrupp Rasselstein, one of Europe’s foremost packaging steel manufacturers, has embarked on a significant digital transformation journey to tackle the complexities of its global supply chain and maintain competitive advantage amid rising industry demands. At the heart of this evolution is the adoption of advanced process mining technology from Celonis, enabling the company to gain unprecedented transparency and efficiency across its operations.
Operating from its extensive German production facility—the largest of its kind globally—thyssenkrupp Rasselstein manages an intricate web of over 300 interconnected IT systems. This complexity historically posed challenges for real-time visibility and swift reaction to supply chain disruptions. The partnership with Celonis over the past three years has revolutionised this landscape by integrating artificial intelligence (AI) and process intelligence solutions to build a data-driven, connected supply chain. This transformation supports proactive risk management, enhances delivery reliability, and optimises critical business processes.
Dr Michael Pullen, CFO of thyssenkrupp Rasselstein, highlighted how, prior to Celonis, limited supply chain visibility hindered responsive decision-making. He explained to industry media that now, with real-time process overviews, the company can manage risks more effectively, reduce excess inventory, and improve delivery accuracy—all of which underpin smoother production planning and better strategic choices.
A foundational element of this digital optimisation is the creation of a ‘digital twin’ of the supply chain. By integrating data from thyssenkrupp Steel Europe with internal production planning systems, the company established a unified data source accessible to all stakeholders. This has enabled swift, actionable insights across more than ten core processes and over 50 use cases, including procure-to-pay, order-to-cash, inventory management, warehouse operations, and accounts receivable.
The results are tangible: proactive prevention of material shortages, optimal safety stock levels, improved delivery accuracy, and notable working capital savings via efficient inventory and financial management. Additionally, Celonis’ Action Flows automate routine tasks such as purchase order creation, freeing staff to prioritise strategic activities.
AI integration forms a critical pillar in this smart supply chain architecture. Employees now leverage the AI-powered Celonis Copilot to conduct natural-language queries and interpret complex data without requiring deep analytical expertise, expediting decision-making processes. On the shop floor, a Process Copilot provides near real-time updates on production material status, fostering operational agility. Moreover, AI minimises waste from unsold materials by identifying the best customer matches for excess stock, validated by human input, and facilitating targeted outreach through automated communications and response tracking.
Thyssenkrupp Rasselstein’s digital strategy encompasses more than supply chain enhancements. The firm has also adopted the Workerbase Connected Worker platform to streamline frontline operations, cutting task times by 26% and eliminating redundancies within ten weeks of deployment. This platform empowers workers to innovate continuously by developing tailored digital solutions, further embedding a culture of ongoing improvement.
Furthermore, the company has implemented the PSImetals production management system, integrating modules for production, quality, logistics, planning, and order scheduling. This system supports approximately 1,000 employees across three shifts, standardising and improving production efficiency and enabling flexible responses to market demands.
Customer engagement is being transformed through digital tools such as an enhanced Packaging Steel App, allowing swift, digital submissions of complaints with multimedia support and immediate notification to relevant teams. Similarly, the redesigned SteelOnline platform bolsters customer service digitalisation with a user-friendly interface and AI-driven chatbot assistance, reducing processing times and enhancing transparency and interaction efficiency.
Clarissa Odewald, CEO of thyssenkrupp Rasselstein, has spoken about the company’s broader commitment to digital innovation. Initiatives like internal hackathons foster collaborative development of software solutions tailored to optimise products and processes, thereby advancing economic, ecological, and social performance.
In sum, thyssenkrupp Rasselstein’s multifaceted digitalisation programme—from supply chain process mining and AI integration to frontline worker empowerment and customer service digitalisation—is setting new standards for operational excellence in the steel packaging sector. By harnessing cutting-edge technology and fostering a culture of innovation, the company is ensuring resilience and agility in an increasingly dynamic global market.
Source: Noah Wire Services
