Batesville Tool & Die Enhances Manufacturing Efficiency with Plex Cloud ERP Integration

Batesville Tool & Die is a global supplier of precision metal stamping components for the automotive, appliance, industrial, and other industries. The company operates ISO/TS-certified facilities in Batesville, Indiana and Queretaro, Mexico. As a full-service supplier, Batesville has a wide range of capabilities, including metal stamping, welding, and assembly. With over 30 years of experience, Batesville Tool & Die has established itself as a leader in producing complex stampings and welded assemblies, with stamping capabilities ranging from 50 to 1,200 tons. The company is committed to maintaining high standards of quality and efficiency, which is evident in its ISO/TS-certified facilities. Batesville Tool & Die's operations span across the U.S. and Mexico, allowing it to serve a diverse range of industries with precision and expertise. The company's dedication to innovation and efficiency has driven its success in the competitive metalforming industry.

For more than a decade, Batesville Tool & Die had used multiple data systems to manage its various business and manufacturing processes. These custom applications barely communicated with each other—and they couldn’t integrate the company’s plant in Mexico. Batesville sought a leaner, more efficient operation that could help it keep pace with today’s data-driven business environment. With facilities in Batesville, Indiana, and Queretaro, Mexico, Batesville Tool & Die is a global supplier of precision metal stamping components for automotive, appliance, and other industries. For more than 30 years, Batesville Tool & Die has produced complex stampings and welded assemblies, with stamping capabilities ranging from 50 to 1,200 tons. For more than a decade, the company had multiple data systems to manage various business and manufacturing processes that barely communicated with each other. Interested in a more efficient and leaner operation in today’s data-driven business environment, Batesville Tool & Die turned to Plex for an integrated enterprise resource planning (ERP) solution.

Batesville Tool & Die turned to Plex for an integrated enterprise resource planning (ERP) solution to address its challenges. Plex Manufacturing ERP is a cloud ERP solution built specifically for the manufacturing enterprise. Prior to using Plex Cloud ERP, Batesville’s machine presses were integrated using custom software. Although the software was effective, it lacked the ability to expand into other locations, including the company’s Mexico plant. Plex Systems’ partner Kors Engineering integrated the shop floor PLCs with Plex, enabling seamless, real-time communication. In addition to the consistent interface for operators, Plex also has allowed for a more efficient manufacturing process by automating many functions, including label printing when containers are full. What’s more, Plex has made the monitoring and interaction between plants in Indiana and Mexico more efficient. Plex Cloud ERP provides control plans, which have become an integral part of production as they track the activities on the shop floor. At Batesville’s plants, control plans track the engineering quality of parts and provide consistent and timely communication to operators regarding specifications, setup, and operation instruction to manage the processes with minimum errors to produce good quality product. Plex has made it easier for the operators at Batesville to enter data into the onscreen checksheets that are fully integrated with, and driven from, control plans. Now, inspection data is fed directly into easy-to-use checksheets, validated against the specifications limits, and stored in the Plex database for the consistent management of the manufacturing process. This data is accessible anywhere, anytime, ensuring efficiency in the process. The checksheets also support pictures and drawings, color-coding, and other features to make them even more effective.

• Integrated plants across the U.S. and Mexico, enabling real-time communication with the shop floor.
• Enhanced visibility into supplier inventory, allowing for better management and planning.
• Automated many manufacturing processes, leading to increased efficiency and reduced manual intervention.
• Plex's interface, VisionPlex, allows users to control the look and usability of their systems, improving work efficiencies and performances.
• Plex has enabled the company to integrate all of its administrative, engineering, production, and manufacturing processes.