Master Data Migration for Plant Maintenance & Material Management: From ECC/Legacy Systems to S/4HANA
In industries like steel manufacturing and mining, where asset reliability and inventory precision are critical, clean, structured, and validated master data is the foundation for operational excellence.
With many enterprises transitioning from SAP ECC or non-SAP legacy systems to S/4HANA, migrating Plant Maintenance (PM) and Material Management (MM) master data becomes a complex but critical task. This blog walks through how Master Data Services (MDS) and Power Query tools are used to streamline this process with business users' collaboration.
Why Master Data Migration Matters in Steel & Mining
- Inaccurate equipment data → Missed PM schedules → Unplanned failures
- Unclean material masters → Overstocks or stockouts → Delay in shutdowns
- Legacy inconsistencies → Failed validations in S/4HANA → System disruptions In short: Bad data breaks good systems.
Our Migration Approach: ECC/Non-SAP ➜ S/4HANA
We follow a staged, collaborative approach that combines technical tools with deep domain involvement.
1. Extraction
We pull master data from SAP ECC, spreadsheets, or non-SAP legacy system
- Volume checks per object (equipment, material, vendor)
- Null, blank, and inconsistent field identification
- Source vs target count validation logs
- Early engagement of business for extraction gaps
- PM: Functional Locations, Equipment, Maintenance Plans, Task Lists, Measuring Points, Catalogs
- MM: Materials Master, BOMs, Vendor Master, Purchase Info Records
2. Transformation
Using Power Query, we:- Clean, reformat, and enrich legacy data
- Map fields to new S/4 structures
- Apply logic-based transformations (e.g., status handling, UoM conversions)
Business rules and logic are reviewed in joint sessions with plant and procurement teams
3. Data Cleansing & Standardization
In collaboration with business users:- Duplicate detection and removal using fuzzy logic
- Naming conventions and code standardization (especially in equipment and material master)
- Validation against equipment hierarchy or classification standards
In mining and steel plants, common issues like duplicate equipment tags or conflicting material descriptions are resolved during this phase.
4. Load & Migrate
- Mock uploads using SAP Migration Cockpit, BDC,LSMW, BAPI.
- Log-based testing for upload failures and success ratio.
- Unit test reports for each master data object
- Peer testing with IT + business
Where applicable, we use Power Query outputs to prepare clean flat files for direct upload.
5. Functional Testing in Quality System
- Test cases: Create Notification, PR/PO simulation, IW31, IL03.
- Role-based testing by Maintenance, Stores, Purchase teams.
- Structured test scripts with pass/fail and defect log.
- Validation dashboards shared with business SMEs.
6. User Acceptance Testing (UAT)
- Final round of business validation.
- Real business scenarios run on migrated data.
- Issue logs maintained with resolution TAT.
- Business sign-offs and confidence tracking.
7. Pre & Post Load Validation
We implement:- Pre-validation reports (e.g. Business rule based validation of Master data, missing classification, duplicate materials).
- Post-load reconciliation (e.g., count checks, data matching).
- Stakeholder sign-off via automated data validation dashboards.
In one steel plant project, post-migration validation uncovered misaligned spare part descriptions that would have halted SAP procurement flows – all resolved before go-live!
8. Handover Documentation: Transparent Knowledge Transfer
We prepare and share:- Data dictionaries and field mapping logs.
- Transformation logic documents.
- Error logs and resolutions.
- Functional and data validation sign-offs from business stakeholders.
- User training content tailored to migrated data structures.
This helps internal IT and business teams take full ownership of their master data going forward.
9. Post Go-Live Support: Stability After Cutover
We stay engaged beyond go-live with a structured support approach:
Hypercare Support- Real-time issue tracking and resolution.
- Support for functional users struggling with new structures or codes.
- On-the-spot corrections for any missed or misaligned records.
Co-Working with Business: A Game-Changer
Unlike purely IT-driven migration projects, we embed business SMEs (Maintenance Engineers, Storekeepers, Purchase Officers) into every phase:
- To identify functional relevance.
- To validate data quality before uploads.
- To ensure the S/4HANA system reflects ground reality.
This is particularly crucial in steel plants with legacy data spanning 20+ years and remote mining operations with inconsistent connectivity or system practices.
Final Thoughts
Master data migration is not just an IT exercise—it’s a transformation of how business operates.
By combining Master Data Services, Power Query, and business engagement, we’ve helped steel and mining organizations confidently shift to S/4HANA while maintaining full control over their asset and material ecosystem.