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SPF also lacked full plant floor visibility in their existing ERP system, with employees struggling to access real-time production status and resorting to manual searches. This slowed operations, leading to gaps in communication and inefficiencies in workflow. Another difficulty SPF faced was the ability to obtain meaningful and trustworthy data. The measurement of Cost of Quality through internal scrap, external rejects, and rework was inconsistent, negatively impacting quality recording.  Recognizing the need for a stronger solution, SPF began the search for a new, cloud-based ERP system that could address numerous requirements. The company sought a platform capable of improving job scheduling, enhancing operational cost visibility, and consolidating various functions such as accounting, production control, material management, and record retention into a single system.

A Team Effort For Implementation

A team of SPF employees, including ownership, IT, quality, production, and other key stakeholders, assembled to select the new system. After a rigorous evaluation process involving three potential solutions, SPF ultimately selected Plex ERP.

Plex stood out due to its ability to surpass SPF’s needs, its avoidance of subscription-based pricing models, and the proactive support provided by Plex implementation partners. Additionally, Plex provided comprehensive product demonstrations and connected SPF with an existing customer, which further increased SPF’s confidence that Plex ERP offers the best combination of features and functionality to address their needs.

The Plex-SPF relationship officially began in December of 2021 with training beginning promptly, and by August of 2022, SPF was live on Plex. The success of this 9-month implementation process is attributed to the efforts of the SPF team, Plex, and implementation partner Control+M Solutions.

With the help of Control+M, SPF developed a diligent implementation approach. They created structure around their plan, utilizing various checklists to ensure no detail was overlooked and carried out weekly team meetings where tasks were assigned and prioritized. Four individuals from SPF were also in charge of reviewing existing data necessary for the migration to Plex’s ERP. Interactive training sessions provided by Plex assisted in fostering a smooth system transition. Although demanding, this process proved to be highly beneficial.

Despite encountering a few challenges along the way, SPF’s implementation journey highlights the importance of planning, communication, and a willingness to adapt. This combination ultimately led to the team’s successful go-live.  

SPF America's Revitalizing Results

Since implementing Plex, SPF America has experienced a significant transformation in their daily operations, marked by enhanced visibility and efficiency across all processes. The company now has unprecedented visibility into their shop floor operations, allowing employees to better anticipate and manage potential disruptions. Moreover, SPF has improved control over production costs, a critical aspect for maintaining profitability in the competitive metal forming market.

Through utilization of IntelliPlex, an integrated data visualization and analytics platform, SPF is now able to automate the tracking of all business processes, providing real-time insights through intuitive dashboards displayed across the shop floor. This increase in available information, including metrics such as on-time delivery (OTD), overall equipment effectiveness (OEE), and scrap, enables daily reviews with shop leads, encouraging continuous improvement and focused attention on KPIs. The access to real-time data has also streamlined order expediting processes, leading to increased profitability and agility in response rates to customers.

Throughput, although already robust, has been further optimized with Plex’s comprehensive visibility into shop floor operations. Productivity gains have been realized through enhanced monitoring capabilities and reporting functionalities and Plex’s accuracy in providing OEE metrics has surpassed the previous system. One additional exciting benefit is SPF’s margin growth of over 10%. Despite complexities that arose from SPF’s multiple locations and differing go-live dates, the integration process continues, promising further enhancements over time.  Employee engagement and confi dence has increased following the Plex implementation, driven by monthly meetings to foster understanding and alignment with organizational goals. The streamlined processes and enhanced access to data have empowered employees to embrace change and actively provide valuable input. SPF has also been able to significantly reduce their temporary workforce, shifting from 20 to 3 employees. Additionally, the company increased sales without increasing headcount.

Plex has revolutionized SPF’s operations, providing a comprehensive system that enhances production visibility, problem-solving capabilities, and overall efficiency. The improved access to data has enabled SPF to thrive in the dynamic manufacturing environment, achieving operational excellence while maximizing profitability.