Case Study

Moldtech Inc. Saves Time, Money, and Resources with Plex Smart Manufacturing Platform

Since implementing Plex, the rubber mold manufacturer has improved efficiency and found savings across company operations

Type Case Study Industry Rubber Molding Location Lancaster, New York

• Delayed and inaccurate reporting due to poor plant floor visibility
• Limited digitization hindering access to trustworthy data

• Lacked control over materials and finished goods and had near zero inventory accuracy

Solution

Plex Enterprise Resource Planning (ERP)
Plex Manufacturing Execution System (MES)

Plex Quality Management System (QMS)
Plex MES Automation and Orchestration (MES A&O)

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Results

Decreased the cost of scrap by nearly 50%
Improved efficiency by 10-20%
Achieved a strong culture of quality

Found approximately $25,000 in savings in the first quarter of 2025

Leaving Disparate Systems in the Past

As a leading North American manufacturer of rubber molded products, Moldtech Inc. has experienced its fair share of evolution over the past 25 years. With a desire to continue progressing and a focus on both scalability and quality, the team noted gaps between what they wanted to achieve and what was possible with their legacy system. The existing infrastructure featured very basic functionality, forcing Moldtech to utilize additional software and excel spreadsheets for various reporting and tracking requirements.

“We wanted a solution that gave us real time inventory levels, live production metrics, and accurate costing,”

EDWARD HALADY

President, Moldtech Inc.

The company’s existing lack of digitization, plant floor visibility, and control of materials resulted in delayed reporting and inaccurate data. This led the Moldtech team to search for a new, unified digital system that connected business and plant floor operations.

close-up photo of black rubber O-rings and coiled tubing arranged in white trays on a beige surface

Progress Leads to Plex

The hunt for a holistic MES system kicked off with an evaluation period. Moldtech team members researched various solutions on the market and compiled viable options. After devising a shortlist, the team dove deeper and talked to real users, sat in on in-depth demonstrations, and ultimately completed an internal ranking survey and selection matrix. Finally, with two potential options on the table, Moldtech completed pricing negotiations and additional demonstrations before landing on the Plex Smart Manufacturing Platform.

Moldtech took a team approach to their Plex implementation, allowing individuals to take the lead based on the areas of Plex most applicable to their job roles. This unique and collaborative process proved to be a necessity as the company simultaneously restructured their organization, rebuilding the team amidst the implementation. However, what could have been a downfall was described by Halady as relatively seamless. Moldtech brought new team members in and trained them directly within Plex, allowing the onboarding process to naturally blend with the implementation.

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Decreased Scrap, Increased Growth Opportunities

Moldtech successfully implemented Plex in six months and began seeing results almost immediately. The company realized increased efficiency, decreased scrap, and cost savings, allowing them to continue pursuing the goal of producing quality and cost-effective products.

End-of-week reviews that once required a manual compilation of scrap data and creation of charts now use detailed data pulled directly from Plex. This has increased awareness across the board, giving all team members access to scrap trends, dollar values, percentage of sales, and more. Now, everyone on the shop floor can be motivated based on real data, saving time, and increasing efficiency.

As Moldtech works to fully implement Plex MES A&O, there is no doubt that their data will only continue to improve.

The transition to Plex also significantly reduced scrap, decreasing the cost by nearly half. Moldtech saved approximately $25,000 in the first quarter of 2025 compared to the anticipated budget, attributing the savings to efficiency and insights enabled by Plex technology. Halady noted that the team initially budgeted lower numbers than in previous years, based on the improvements seen within Plex in 2024.

“We have live scrap reporting available to us now, allowing us to know exactly what impact our scrap will have on month end bottom-line,” shared Halady.

blurred close-up photo of black cylindrical machine parts arranged on a white surface

A Confident and Efficient Team

The Moldtech team has also seen efficiency increase between 10% and 20%. This change has impacted all areas of business, from being under budget for labor and efficiency, to promoting a culture of quality on the shop floor.

With Plex in place as the company’s production backbone, the team is confident that they will continue to make strides as an organization and find new ways to use the exciting capabilities at their fingertips. Before Plex, the Moldtech team encountered many hurdles when trying to meet production expectations. Now, guesswork has been removed, and the team can better focus on production needs and how to leverage Plex to meet their goals.

Newfound Accounting Capabilities

Moldtech Inc. attributes much of their success with Plex to the robust accounting capabilities. Transactions are now easily accessible, and the team can anticipate month-end figures well in advance. In fact, during the first quarter of 2025, the company posted $4 million in sales and the projected financials were within just $2,500 of the actual results. This remarkable accuracy highlights their improved visibility into costs and margins.

“We’ve never had such accurate reporting. We can truly rely on our cost data to make informed business decisions. It’s been a huge win for us,”

EDWARD HALADY
President, Moldtech Inc.

Positioned for the Future

Prior to implementing Plex, Moldtech lacked systemization and scalability. They were working on disparate systems that lacked trust and didn’t allow for progress without a dramatic change.

“We wouldn’t be where we are without Plex.”

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