Loading
Utility Header Logo
Plex Community
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language
US | EN
Plex, a Rockwell Automation Company logo
Products
Manufacturing Execution System (MES)
Manufacturing Execution Suite (MES) is a comprehensive manufacturing software solution that provides real-time, paperless production management to drive enterprise-wide compliance, quality, and efficiency.
Quality Management System (QMS)
Quality Management System (QMS) is a cloud-based digital quality solution for manufacturers that standardizes and automates quality documentation, processes, and measurements.
Enterprise Resource Planning (ERP)
Enterprise Resource Planning (ERP) is a full-featured, scalable, cloudbased ERP that automates front- and back-office processes.
Supply Chain Planning (SCP)
Supply Chain Planning (SCP) combines data from your Plex ERP and multiple departments across your business to sync up demand and supply planning to improve inventory accuracy and production management.
Connected Worker
Connected Worker empowers frontline manufacturing teams with real-time digital tools to improve productivity, reduce errors, and enhance collaboration. It connects your people, to purpose, people, productivity, and processes to drive continuous improvement and workforce agility on the shop floor.
Production Monitoring
Production Monitoring provides seamless connectivity to machines on the plant floor, delivering transparent, real-time operational KPIs and dashboards to drive continuous improvements.
MES Automation & Orchestration
MES Automation & Orchestration connects your Plex MES to the plant edge to control information flow, processes, and workcenter setup adding efficiency, saving costs, and eliminating manual errors.
Asset Performance Management (APM)
Asset Performance Management (APM) combines process, operational, and machine-level data through highly visual dashboards to proactively monitor machine and plant health to ensure optimal uptime, throughput, and maintenance needs.
Finite Scheduler
Finite Scheduler is an advanced production scheduling tool that helps manufacturers optimize resources, reduce bottlenecks, and improve on-time delivery. It enables dynamic, constraint-based scheduling to align operations with real-world capacity and demand
Platform
Smart Manufacturing Platform Overview
Discover how our integrated platform connects, automates, tracks, and analyzes your operations.
Cloud Infrastructure & Security
Enterprise-grade cloud infrastructure with industry-leading security and compliance.
Mobile Application
Access critical manufacturing data and controls from anywhere with our mobile apps.
Availability & Performance
Industry-leading uptime and performance with 99.5% availability guarantee.
Manufacturing Automation
Seamless integration with Rockwell Automation and other manufacturing systems.
Industries
Aerospace Auto and Tire Food & Beverage Industrial Manufacturing Plastics & Rubber Precision Metalforming
Plex Generic Dark Background
INTERACTIVE DEMO
Plex MES for Automotive

Gain Real-Time Visibility and Control of Your Operations

Try Now
Resources
All Resources Success Stories Analyst Reports Knowledge Articles Demos Blog
Plex Generic Dark Background
Analyst Report
2025 Gartner® Market Guide for Manufacturing Execution Systems
Read More
TALK TO US
SEE A DEMO
Log In Plex Manufacturing Cloud Plex Classic
TALK TO US
SEE A DEMO
Case Study
Recent ActivityRecent Activity

Plex Revolutionalizes Ralco Industries

Download Case Study

Share This:

LinkedInLinkedIn
XX
FacebookFacebook
PrintPrint
EmailEmail

 

Lacking a single system that included MRP, PLC integration, and shipping and receiving, Ralco Industries found that inventory accuracy was a major issue. This inaccuracy led to overstock to ensure there was enough material on hand for jobs. Setups were not consistent, resulting in excessive overtime and expedited shipments. These issues led Ralco Industries to Plex.

At A Glance

  • 60% reduction in scrap, and the company cut downtime and employee turnover
  • 15% reduction in inventory on hand
  • 20% reduction in premium freight costs—expediting is rare Reduced training hours by more than
  • 50% due to system’s ease of use

We get more advantage from Plex than we could with SAP or a similar system. This is the system of the future. Any company looking to outperform its competition and invest for the future will find its way to Plex.

Jim Piper - President, Ralco Industries
 

Ralco Industries was looking for a system that could improve processes, efficiency, and insight. Operations began to suffer from inaccurate data and a lack of visibility.

“In past years, our inventory accuracy was only about 50 percent,” says Jim Piper, President of Auburn Hills, Michigan-based Ralco Industries. “We conducted grueling physical inventories every month, and they would be off within the following week. We never knew if we had enough parts to build a setup.”

“Every time we did a setup, it was different. Each of our guys had his own method. This resulted in lost time, inconsistent product quality, scrap, expedited shipments, etc. We knew we had to fix our system.” Says Piper, “The lack of accurate data from our systems was causing a number of expensive issues—quality problems, scrap, overtime, expedited shipments, etc. We had to get our systems to work for us.”

Seeking One Solution

Given these and other challenges, Ralco’s goal was to find one system that could integrate all facets of its manufacturing business.

Ralco wanted to move away from separate manufacturing resource planning (MRP) incapable of machine PLC integration. Ralco also wanted to avoid stand-alone software for shipping and receiving.

After a detailed search, the company found that the Plex Manufacturing Cloud offered the most advantages over other solutions. The industryleading manufacturing cloud solution is fully integrated with the PLCs for all shop floor and engineering equipment.

The company noted that Plex could adapt to its unique business strategy and be customized to Ralco requirements. Says Piper, “Every other software company required us to adapt to their software.”

An Improved Process

“After switching to Plex, we now cycle inventories. Because of our improved accuracy in inventory, we can do setups faster, and we have been able to reduce our inventory on hand by 15 percent. Plex also has a ‘recipe’ system for setups, so each setup is exactly the same.

“There is no room for operator variation. If someone attempts to change the recipe, Plex communicates with the PLC and the press stops.”

Ease of Use

The Plex Manufacturing Cloud uses a simple, web-based interface and places few requirements on the operator.

Unlike software from other companies, Plex is accessed through a web browser. This allowed Ralco to avoid the cost and hassle of buying, installing, and maintaining the software and server.

Plex also supports and enhances the system, including all software upgrades, data backup, and professional system management, at its headquarters in Troy, Michigan.

Safe and Secure

According to Ralco, it was a relief to offload the major database and back-up responsibilities, although security was a big issue. In fact, the company reports that a staff member in the IT Department used to work for the CIA. He spent a month trying to break into the Plex system. He never could do it.

Says a Ralco representative, “Plex is an IT department on call, and because they maintain and upgrade everything for us, I’m now a one-man IT department. I handle network issues, PC software, etc., but Plex handles everything with their system. They are responsive and fast, and they care about the customer. Most issues can be addressed with a simple email.”

Fast Implementation

Ralco started its implementation with the Plex Purchasing function. Plex is designed so that you can add one function at a time or simultaneously install several. Ralco can now easily match receipts to internal purchase orders, and match purchase orders to invoices. The company has more control and security over purchase orders, and has actually reduced the number of purchase orders.

The improved efficiency saves about $100 per purchase order processed. After Ralco’s old MRP system crashed, the company took the plunge and subscribed to Plex functions including: Sales/ Customer Relationship Management, Materials, Inventory, Production Tracking, Scheduling, Shipping, Quality, Management, Communication, EDI, System Administration, and Security functions.

“Our Plex rep, Mig O’Brien, developed a plan on how to design, develop, and implement these functions, and they followed it,” says Piper.

“One thing we had learned from previous software companies is that you have to have an internal project manager and a dedicated person from the software company. They work with each other as backups, and it’s the only way to ensure the coordination required.”

Real Benefits, Real ROI

The Plex Manufacturing Cloud is so easy to use that Ralco was able to reduce training hours by more than 50 percent.

“Plex has the same Control Panel for every work area, which simplifies training,” says Piper. “Before, 90 percent of our training time was spent on computer training. But Plex is easy for employees to pick up. Now each employee can run every type of equipment. That’s huge.”

Results were huge too. Products are now of a consistent high quality. Premium freight costs were reduced by more than 20 percent per year. Now it’s a rare event to have to expedite a shipment.

Scrap rates are down by more than 60 percent. Downtime and employee turnover have both been reduced drastically. Inventory is down. Setup times have been reduced. And the paperwork and order tracking are now easy. “We were looking for a two-year payback, but it only took just over a year,” says Piper.

About Ralco Industries

Ralco Logo

Ralco Industries, Inc., is an ISO/TS 16949-certified tier-one and -two automotive supplier specializing in precision welded assemblies, metal stamping, design, tooling, and prototyping. The company serves worldwide OEMs with exhaust, steering, chassis, suspension, seating, and HVAC parts and assemblies.

Industry: Automotive | Precision Metalforming

Location: Auburn Hill, MI

Topics: Automotive Precision Metalforming

Featured Resources

Loading
Loading
Loading
  1. Chevron LeftChevron Left Homepage Chevron RightChevron Right
  2. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
  3. Chevron LeftChevron Left Plex Revolutionalizes Ralco Industries Chevron RightChevron Right
Products
Manufacturing Execution System (MES) Quality Management System (QMS) Enterprise Resource Planning (ERP) Supply Chain Planning (SCP) Connected Worker Production Monitoring MES Automation & Orchestration Asset Performance Management (APM) Finite Scheduler
Platform
Smart Manufacturing Platform Cloud Infrastructure & Security Mobile Application Availability & Performance Manufacturing Automation
Resources
All Resources Case Studies Analyst Reports Knowledge Articles Demos Blog
Industries
All Industries Aerospace Auto and Tire Food & Beverage/CPG Industrial Manufacturing Plastics & Rubber Precision Metalforming & Fabrication
Services & Support
Customer Success & Advocacy Support Services Educational Services Professional Services Plex Community
Get Started
Request a Demo Download Resources Read Success Stories Webinars Contact Support
Company
About Us Why Plex Recognition Newsroom Careers Contact Us
Knowledge Articles
Types of Quality Management Systems The MES Beginner Guide A Guide to Production Part Approval Process What is Industry 4.0? A Guide to Advanced Product Quality Planning Supply Chain Planning: A Guide to Strategic Planning and Operations MES and the Future of Robotics Automation Cloud Based MES Basics Food Manufacturing Software: Why MES Is Critical for Food and Beverage Manufacturers Guide to Failure Mode and Effects Analysis (FMEA) Cloud-Based MES Solutions A Guide to Monitoring Machine Performance What is Connected Manufacturing and Why Should You Care About It?
Privacy & Cookie Policy
Terms & Conditions
Cookie Preferences
Accessibility Settings
Trust Center
© YYYY Plex, by Rockwell Automation. All rights reserved.
© YYYY Rockwell Automation, Inc.