Plex Systems > Case Studies > Aaron Thomas Company Leverages Plex Manufacturing Cloud for Enhanced Inventory Management and Customer Satisfaction

Aaron Thomas Company Leverages Plex Manufacturing Cloud for Enhanced Inventory Management and Customer Satisfaction

Customer Company Size

Mid-size Company

Region

America

Country

United States

Product

Plex Manufacturing Cloud

Tech Stack

Cloud ERP
Web-based Customer Portal

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Customer Satisfaction
Cost Savings

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)

Applicable Industries

Food & Beverage

Applicable Functions

Quality Assurance
Warehouse & Inventory Management

Use Cases

Inventory Management
Predictive Maintenance
Remote Asset Management

Services

Cloud Planning, Design & Implementation Services
System Integration

About The Customer

Aaron Thomas Company is a full-service contract packaging company providing specialist services from bundle wrapping to pouching, pallet displays, and more. The company serves a diverse range of customers, spanning from Fortune 500 companies to small and midsize businesses within the food industry. Located in Garden Grove, CA, Aaron Thomas Company has established itself as a key player in the contract packaging sector, known for its commitment to quality, transparency, and agility. The company has been recognized with accolades such as “Contract Manufacturing Supplier of the Year,” highlighting its dedication to maintaining high performance levels and quality standards. As a fast-growing company, Aaron Thomas Co. understands the importance of strong customer relationships as a competitive advantage. The company operates in highly regulated industries, including food, nutraceuticals, and pharmaceuticals, where inventory tracking, quality control, and traceability are critical. With a focus on securing future growth and maintaining its reputation, Aaron Thomas Company sought to implement a robust ERP system to address its business challenges and support its expanding operations.

The Challenge

As a fast-growing contract packaging company, Aaron Thomas Co. recognized that its customer relationships are a great competitive weapon. But to maintain such rapid growth, the status quo of legacy applications, paper and manual processes just weren’t going to cut it anymore. Aaron Thomas Company had one eye on securing its future growth and the other on maintaining its performance levels and quality. This is something that has earned the company accolades such as “Contract Manufacturing Supplier of the Year” – and it is what drove Aaron Thomas Company to set out to find an ERP that could help solve some of its most pressing business challenges. Dealing with customers in highly regulated industries like food, nutraceuticals and pharmaceuticals, Aaron Thomas needs to track 100 percent of their inventory at all times. And as a contract packager, customers fully rely on them for centralized inventory visibility, quality controls and the traceability to perform recalls in a short period of time. To top it off, it was critical to find a new system that could be implemented quickly and scale with a quickly growing business.

The Solution

Aaron Thomas ultimately implemented the Plex Manufacturing Cloud, coming in 20 percent under budget enabling complete real-time visibility into inventory, automating the quality control process, and providing customers with the transparency and self-service to continue to scale operations. Plus, employees can remotely manage the business across the three distributed plants whether in an airport, car or at a remote office. Now, locating lost inventory is simple because every piece of information is tracked in Plex. What used to take hours, now takes minutes. And the company now has fully standardized quality control and compliance processes in the cloud. Users can instantly monitor which internal and external audits have been completed, when they were performed, and by whom. And best of all, mock recalls can now be conducted in a mere 7 minutes with all documentation sent to a customer in under an hour – a process that previously took several people and several days. In moving to the Plex Manufacturing Cloud, Aaron Thomas has been able to achieve all their goals. The company’s quality department has gone completely paperless with Plex and executes most of their work exclusively on tablets. Mock recalls now happen in a matter of minutes, and customers can access their information 24/7 from anywhere, allowing Aaron Thomas to handle three times as many customers without adding headcount. Best of all, Plex gives Aaron Thomas room to grow well into the future. Cloud-based ERP is almost infinitely configurable, so it can constantly be conformed to a food and beverage manufacturer’s evolving needs.

Operational Impact

The implementation of the Plex Manufacturing Cloud has enabled Aaron Thomas Company to achieve complete real-time visibility into inventory, streamlining operations and enhancing efficiency.
The company has fully standardized its quality control and compliance processes in the cloud, allowing for instant monitoring of internal and external audits.
Employees can now remotely manage the business across three distributed plants, providing flexibility and improving operational efficiency.
The transition to a paperless quality department has been successful, with most work now executed exclusively on tablets, reducing reliance on manual processes.
Customers have 24/7 access to their information from anywhere, enhancing customer satisfaction and allowing Aaron Thomas to handle a larger customer base without increasing headcount.

Quantitative Benefit