Founded in 2021, Advanced Vehicle Assemblies, LLC is known for its unique manufacturing processes that enable the production of complex metal assemblies.
- Urgent need for new ERP system after parting from sister company. This choice marked a pivotal step for the company. They embraced a new ERP system that promised to streamline operations
- Relied on manual processes due to absence of real-time production reporting and inventory tracking
- Significant delays and lack of trust in collected data
- Established real-time production reporting
- Increased insight into inventory tracking
- Enhanced visibility across production
Challenge
Pressed for Time: New ERP Needed
Advanced Vehicle Assemblies (AVA) split from its former sister company in June 2020, kicking off an urgent search for a new ERP system. They were covered under a shared service agreement from their previous affiliation, but the end date was nearing. As a result, the company looked for an ERP solution that minimized hardware maintenance — a stark contrast to their previous experience — and could be implemented within their tight timeline.
Additionally, AVA faced the fact that their old system did not include Manufacturing Execution System (MES) integration. The absence of real-time production reporting and inventory tracking led to reliance on manual processes, causing significant delays and a lack of trust in the collected data. As AVA aimed for rapid independence and organizational rebuilding following the split, the selection of a new ERP system became a critical aspect of their strategic focus.
AVA conducted surveys, evaluations, and demonstrations to help identify their top priorities with the help of user feedback. Despite the tight time frame, the culmination of this rigorous process led them to select Plex as their new ERP system in late 2020. This choice marked a pivotal step for the company. They embraced a new ERP system that promised to streamline operations, enhance efficiency, and support their journey towards becoming a thriving, independent enterprise.
Solution
An Accelerated ERP Journey
Embarking on their Plex ERP system revamp journey, AVA utilized the Milan, Michigan facility as their first Plex implementation site in December 2020. Adding an extra layer of complexity is the fact that this location shared the outdated ERP system with AVA’s sister company. Knowing time was of the essence, the Milan team aimed to go live on Plex within an ambitious 60 days.
To ease the transition, AVA enlisted the support of Plex implementation services, who assigned a project manager to the Milan site. The project manager brought a deep understanding of the project’s parameters and the urgency of a rapid go-live time frame. To bolster their efforts, the Plex team also enlisted outside consultants to assist with the critical data cleansing phase as it was loaded into Plex. Employee training sessions and workshops were also prioritized to prepare users for the impending changes.
As the go-live date loomed, an impressive collaboration unfolded, with up to seven Plex team members present at the Milan location during each shift. The level of teamwork from all sides underscored the collective commitment to a successful implementation. Despite the challenge of a 60-day timeline, the Milan site implemented Plex successfully within the desired time frame. Employees mastered the main Plex functions, navigating the natural learning curve that comes with migrating to a new manufacturing solution.
Result
Transformed Operations with Insights and Data
Rob Arrowsmith, CIO of AVA says, “Before Plex, data was not easily accessible, and functions difficult to learn. Now, real-time data is accessible, and the online learning resources Plex provides are abundant and easy to follow.”
The Plex implementation brought about a transformative wave of improvements for AVA, revolutionizing their operational landscape. Most notably was the establishment of real-time production reporting and inventory tracking. Accessing real-time data instilled a heightened sense of awareness of inventory for AVA, enabling employees to address issues promptly, fostering agility in their responses and elevating overall operational efficiency. The Plex ERP also significantly augmented visibility across production. With operators more engaged and proactive on the shop floor, AVA witnessed quicker problem resolution.
Future Growth Unlocked
The benefits of Plex empowered AVA to successfully grow its business while maintaining a lean operational structure, minimizing the need for additional personnel to manage the Plex ERP system. Key Performance Indicators (KPIs) became more visible and dynamic, seamlessly integrating into Plex rather than being extracted from external Excel sheets.
Plex also eliminated the necessity for financial consolidation software, streamlining processes and making contextual data easily available. The intuitive nature of the Plex system unlocked this accessibility, making it easy for users to navigate and find the information they need. The cloud-based nature of Plex, coupled with its highly configurable background settings, provided a flexibility that enabled AVA to continue to test and implement improvements.
Full Independence and Minimal Support Needed
The company’s most significant achievement with Plex has been the ability to attain complete independence. Upon completion of the implementation, internal surveys affirmed the success of Plex as it earned high marks for reliability, speed, and ease of use. The adoption and integration of the software extends beyond that of the Milan, Michigan location, with AVA employees able to take on the remaining Plex implementations internally with little to no Plex support required on site.
This case study is a replicated version, with the original available on the Plex website. To access the original version, please click here.
Published September 24, 2024
