Accutech Automates and Digitizes with Plex MES A&O

Accutech Mold & Machine leverages real-time Plex ERP data to transform operations, while also automating production processes with Plex MES A&O.

Challenge

• Operated off multiple, unconnected systems that resulted in duplicative entry
• Lost valuable business time due to manual processes
• Lacked insight into real-time production data

Solution

• Plex Enterprise Resource Planning (ERP)
• Plex Manufacturing Execution System (MES)
• Plex MES Automation and Orchestration (MES A&O)

Results

• Transitioned from an 8-hour production data delay to real-time insights
• 70% less audit findings
• Digitized and modernized plant floor operations
• Reduced both on-hand inventory and raw materials
• Automated critical points along production from operator clock-in to label creation

The Search for a Streamlined Solution

AMM is a certified woman-owned business, serving industries such as automotive, agriculture, and defense. The company has 31 injection molding machines that run 24 hours a day—in addition to this manufacturing, AMM also builds and repairs injection molds. With various parts of the business always moving, and operations that have continued to expand, AMM recognized the legacy system no longer provided the infrastructure necessary for success.

“We had one system for accounting, we had another one that would track expenses of jobs, we had one system that would look at productivity of the machines. It was a lot of dual or triple entry on everything that we did,” explains AMM President Kelly Geiger. The lack of a single source of truth resulted in wasted time and resources, with supervisors leaving the plant floor to input production data. The AMM team knew they needed a solution that would allow for business-essential operations to continue without pulling people away from their responsibilities.

Challenge

The Search for a Streamlined Solution

AMM is a certified woman-owned business, serving industries such as automotive, agriculture, and defense. The company has 31 injection molding machines that run 24 hours a day—in addition to this manufacturing, AMM also builds and repairs injection molds. With various parts of the business always moving, and operations that have continued to expand, AMM recognized the legacy system no longer provided the infrastructure necessary for success.

“We had one system for accounting, we had another one that would track expenses of jobs, we had one system that would look at productivity of the machines. It was a lot of dual or triple entry on everything that we did,” explains AMM President Kelly Geiger. The lack of a single source of truth resulted in wasted time and resources, with supervisors leaving the plant floor to input production data. The AMM team knew they needed a solution that would allow for business-essential operations to continue without pulling people away from their responsibilities.

Solution

A Need for Easily Accessed Production

Data When searching for a new ERP system, the AMM team toured the facility of a current Plex customer to see the technology active on the plant floor. Committed to making business decisions in the best interest of its employees, AMM also worked with team leaders to create a list of needs the new solution would ideally address. The Plex Smart Manufacturing Platform was ultimately selected, as it would digitize paper-based processes and cut out unnecessary steps throughout the production process.

“We saw the benefit, from quarter to cash, how much more efficient we could be if we went with Plex. And that’s exactly what we’ve seen since we’ve implemented,” said Davon Geiger, Administrative Support Manager, Accutech Mold & Machine.

A unique aspect of AMM’s Plex implementation was the immediate inclusion of Plex MES A&O. The injection mold manufacturer was particularly interested in the real-time data the Plex product would offer, mainly due to the automation of various processes on the plant floor. With no delay in accessing production data, the team would be able to identify any issues when and where they arise. This piece of the Plex implementation was largely supported by Plex System Integrator Cumulus Consulting, who worked closely with AMM from the very beginning of the implementation process through the company’s successful Plex deployment.

“We worked hand-in-hand with Cumulus to get everything set up to be exactly how we wanted to see the data, doing all the math exactly how we figure it, how it makes sense for us, how it makes sense for our operators, and providing that data back to our people in a way that makes sense to everybody the most,” shares Dylan Geiger, Project Manager, Accutech Mold & Machine.

Results

Enterprise-Wide Improvements

The impact of Plex on AMM’s operations was immediately apparent. The team now had access to data instantly, no longer requiring people to leave the plant floor and report updates or issues in-person. This has saved AMM time, reduced manual labor, and opened the door for innovation. It has also modernized the facility, leaving AMM feeling confident they have future-readied the company by investing in advanced technology.

“We no longer had to wait upwards of 8 hours to hear, ‘Oh, this wasn’t running good.’ Or, ‘We ran 7% scrap on this press.’ ...It was done on the spot and presented to us so that we could see it as it was happening and we could correct the problem immediately,” explains Dylan Geiger.

The Inventory Impact

AMM has also seen an improvement in inventory scheduling and ordering. Since streamlining operations with Plex ERP, managing inventory has become easier and less time-consuming. Previously, production managers would have to walk across the facility and physically check inventory. This process is now digitized and available instantly on the computer. With a fuller picture, AMM has been able to reduce inventory across on-hand inventory and raw materials.

“The implementation of Plex allows me to focus on the goals that need to be met for the company, as far as reducing scrap in the ways of scheduling better or even making sure we get shipments out on time,” states Eric Boyd, Product Support Manager, Accutech Mold & Machine.

Making the Most of Automation

Prior to implementing Plex MES A&O, many of AMM’s processes were on-paper and production data was manually recorded. “We’ve automated almost everything that we can,” shares Dylan Geiger. When operators arrive at a machine, they digitally clock into the press. This creates an easily accessed record of which individual was present during a specific timeframe. While the product runs, AMM no longer waits for machine operators to manually report production. Product labels are automatically created that reflect quantity, direction, and the receiving customer. The real-time production visibility and automation enabled by Plex MES A&O has transformed AMM’s operations, allowing the AMM team to remove pesky manual processes and minimize the impact of manufacturing malfunctions.