Case Studies Double H Plastics, Inc. Improving Manufacturing Automation for Future Success

Edit This Case Study Record

	Double H Plastics, Inc. Improving Manufacturing Automation for Future Success

Double H Plastics, Inc. Improving Manufacturing Automation for Future Success

Technology Category	Functional Applications - Enterprise Resource Planning Systems (ERP) Functional Applications - Inventory Management Systems
Applicable Industries	Food & Beverage Plastics
Applicable Functions	Discrete Manufacturing Quality Assurance Warehouse & Inventory Management
Use Cases	Inventory Management Manufacturing System Automation
Services	Software Design & Engineering Services System Integration
Challenge	Double H Plastics, a manufacturer of high-quality plastic cores for the paper, film, and foil converting industry, was facing challenges due to its growth into the food packaging industry. The company was using a Unix/DOS-based system called Tiny Term, which lacked real-time data and system integration across its enterprise. This was causing inefficiencies and delays in their operations. The company realized it was time to modernize and thoroughly evaluated multiple ERP vendors before selecting IQMS for its familiarity with Double H Plastics’ industry and its comprehensive functionality that required no third-party applications. Read More
About Customer	Double H Plastics, Inc. is a manufacturer of high-quality plastic cores for the paper, film, and foil converting industry and a creator of insert-molded packaging for the dairy, dry goods, and food packaging industry. The company was founded by Harry Harp, who established his company with the development of a high-speed process for extruding round plastic drinking straws to compete with the paper straw industry. Over the years, the company has expanded its operations and currently produces approximately 80 percent of all plastic cores used in the United States. Double H Plastics also manufactures solid plastic tubs and formed paper cups to supply a complete package to its customers. The company has modern extrusion and molding facilities in Warminster, PA, and affiliate manufacturing plants in Marion, IN, and Morristown, TN. Read More
Solution	Double H Plastics selected IQMS for its familiarity with their industry and its comprehensive functionality that required no third-party applications. IQMS provided Double H Plastics with features such as robust scheduling tools and RealTime Production Monitoring system, which gave the company transparent visibility and real-time data management in every aspect of its business. With nearly 1200 wireless RealTime devices recording and gathering data from very short cycle times across multiple plants, Double H Plastics could make proactive decisions and recoup productivity based on immediate production information. Additionally, with increased visibility in scheduling, Double H Plastics could now see bottlenecks in advance and plan ahead to work them out, prior to missing a shipment and disappointing a customer. Read More Log in to view content
Contents

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)

Functional Applications - Inventory Management Systems

Applicable Industries

Food & Beverage

Plastics

Applicable Functions

Discrete Manufacturing

Quality Assurance

Warehouse & Inventory Management

Use Cases

Inventory Management

Manufacturing System Automation

Services

Software Design & Engineering Services

System Integration

Challenge

Double H Plastics, a manufacturer of high-quality plastic cores for the paper, film, and foil converting industry, was facing challenges due to its growth into the food packaging industry. The company was using a Unix/DOS-based system called Tiny Term, which lacked real-time data and system integration across its enterprise. This was causing inefficiencies and delays in their operations. The company realized it was time to modernize and thoroughly evaluated multiple ERP vendors before selecting IQMS for its familiarity with Double H Plastics’ industry and its comprehensive functionality that required no third-party applications.

About Customer

Double H Plastics, Inc. is a manufacturer of high-quality plastic cores for the paper, film, and foil converting industry and a creator of insert-molded packaging for the dairy, dry goods, and food packaging industry. The company was founded by Harry Harp, who established his company with the development of a high-speed process for extruding round plastic drinking straws to compete with the paper straw industry. Over the years, the company has expanded its operations and currently produces approximately 80 percent of all plastic cores used in the United States. Double H Plastics also manufactures solid plastic tubs and formed paper cups to supply a complete package to its customers. The company has modern extrusion and molding facilities in Warminster, PA, and affiliate manufacturing plants in Marion, IN, and Morristown, TN.

Solution

Double H Plastics selected IQMS for its familiarity with their industry and its comprehensive functionality that required no third-party applications. IQMS provided Double H Plastics with features such as robust scheduling tools and RealTime Production Monitoring system, which gave the company transparent visibility and real-time data management in every aspect of its business. With nearly 1200 wireless RealTime devices recording and gathering data from very short cycle times across multiple plants, Double H Plastics could make proactive decisions and recoup productivity based on immediate production information. Additionally, with increased visibility in scheduling, Double H Plastics could now see bottlenecks in advance and plan ahead to work them out, prior to missing a shipment and disappointing a customer.

Impact #1	Eliminated previous third-party interfacing and gained the ability to schedule and track production data in real time and within one comprehensive package.
Impact #2	Increased warehouse efficiency in product movement by 20 percent.
Impact #3	Eliminated all inventory movement paperwork.

Impact #1

Eliminated previous third-party interfacing and gained the ability to schedule and track production data in real time and within one comprehensive package.

Impact #2

Increased warehouse efficiency in product movement by 20 percent.

Impact #3

Eliminated all inventory movement paperwork.

Benefit #1	Saved significant employee labor time equaling about 30 percent of an eight hour shift per warehouse person, resulting in a savings of approximately $100,000 per year.

Benefit #1

Saved significant employee labor time equaling about 30 percent of an eight hour shift per warehouse person, resulting in a savings of approximately $100,000 per year.

Download PDF Version

Overview

Double H Plastics, Inc. Improving Manufacturing Automation for Future Success

Operational Impact

Quantitative Benefit