Case Studies IQMS Helps Plastic Components, Inc. Set the Leading Edge of Automated Manufacturing

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	IQMS Helps Plastic Components, Inc. Set the Leading Edge of Automated Manufacturing

IQMS Helps Plastic Components, Inc. Set the Leading Edge of Automated Manufacturing

Technology Category	Analytics & Modeling - Real Time Analytics Functional Applications - Enterprise Resource Planning Systems (ERP) Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Electronics Equipment & Machinery
Applicable Functions	Discrete Manufacturing Quality Assurance
Use Cases	Manufacturing System Automation Predictive Maintenance Real-Time Location System (RTLS)
Services	Software Design & Engineering Services System Integration
Challenge	Plastic Components, Inc. (PCI) is a world-class injection molder of plastic parts. The company has established a reputation as a visionary manufacturer because it runs fully automated facilities: no direct labor is involved in their manufacturing process. However, at a little over a decade into their development, PCI’s information system was a potpourri of Excel spreadsheets, Access databases, and legal pads with pencils. They didn’t have a good handle on production scheduling, inventory, and true manufacturing costs. To address this situation, PCI conducted an assessment of a number of ERP systems, including IQMS. PCI committed to IQMS’ Manufacturing ERP, and spent nine months getting ready for implementation. Read More
About Customer	Based in Germantown, Wisconsin, Plastic Components, Inc. (PCI) is a globally competitive, low-cost producer of critical injection molded thermoplastic parts for original equipment manufacturers. Since 1989, the Wisconsin based company has relied on complete process automation to provide the highest quality parts at the lowest possible cost. With 40 dedicated manufacturing cells (presses, robots, parts conveyors and automated material handling systems) producing parts on a fully automated basis 24 hours a day, five days a week, PCI has shipped over one billion molded parts to customers throughout North America since its inception in 1989. Read More
Solution	IQMS’ Manufacturing ERP was implemented as the cornerstone of PCI's operation. The system supports the sophisticated automation the company instituted, allowing them to set up the process and the job, then run for prolonged periods of time. The system builds the buckets and work orders for every job they have, and determines when raw material is needed based on run times and must start dates from the customers. All the functions are scheduled on the floor. It defines exactly how many hours a sales order will need, and allows them to queue up the job that will follow. The system also provides PCI the functionality and planning to manage the complexity and direct operations, and does so with very limited input from PCI personnel. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Functional Applications - Enterprise Resource Planning Systems (ERP)

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Electronics

Equipment & Machinery

Applicable Functions

Discrete Manufacturing

Quality Assurance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Real-Time Location System (RTLS)

Services

Software Design & Engineering Services

System Integration

Challenge

Plastic Components, Inc. (PCI) is a world-class injection molder of plastic parts. The company has established a reputation as a visionary manufacturer because it runs fully automated facilities: no direct labor is involved in their manufacturing process. However, at a little over a decade into their development, PCI’s information system was a potpourri of Excel spreadsheets, Access databases, and legal pads with pencils. They didn’t have a good handle on production scheduling, inventory, and true manufacturing costs. To address this situation, PCI conducted an assessment of a number of ERP systems, including IQMS. PCI committed to IQMS’ Manufacturing ERP, and spent nine months getting ready for implementation.

About Customer

Based in Germantown, Wisconsin, Plastic Components, Inc. (PCI) is a globally competitive, low-cost producer of critical injection molded thermoplastic parts for original equipment manufacturers. Since 1989, the Wisconsin based company has relied on complete process automation to provide the highest quality parts at the lowest possible cost. With 40 dedicated manufacturing cells (presses, robots, parts conveyors and automated material handling systems) producing parts on a fully automated basis 24 hours a day, five days a week, PCI has shipped over one billion molded parts to customers throughout North America since its inception in 1989.

Solution

IQMS’ Manufacturing ERP was implemented as the cornerstone of PCI's operation. The system supports the sophisticated automation the company instituted, allowing them to set up the process and the job, then run for prolonged periods of time. The system builds the buckets and work orders for every job they have, and determines when raw material is needed based on run times and must start dates from the customers. All the functions are scheduled on the floor. It defines exactly how many hours a sales order will need, and allows them to queue up the job that will follow. The system also provides PCI the functionality and planning to manage the complexity and direct operations, and does so with very limited input from PCI personnel.

Impact #1	60 fully automated manufacturing cells running “lights out” 24/7
Impact #2	Consolidated the scheduling function into a single role
Impact #3	Detailed visibility into the profitability of each part produced

Impact #1

60 fully automated manufacturing cells running “lights out” 24/7

Impact #2

Consolidated the scheduling function into a single role

Impact #3

Detailed visibility into the profitability of each part produced

Benefit #1	Growth by a factor of 10

Benefit #1

Growth by a factor of 10

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Overview

IQMS Helps Plastic Components, Inc. Set the Leading Edge of Automated Manufacturing

Operational Impact

Quantitative Benefit