Plex Systems > Case Studies > Creative Foam Corporation Transforms Operations with Plex Cloud ERP for Enhanced Efficiency

Creative Foam Corporation Transforms Operations with Plex Cloud ERP for Enhanced Efficiency

Customer Company Size

Mid-size Company

Region

America
Asia
Europe

Country

United States

Product

Plex Cloud ERP

Tech Stack

Cloud ERP
Software as a Service (SaaS)

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Cost Savings
Digital Expertise

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)
Platform as a Service (PaaS) - Data Management Platforms

Applicable Industries

Automotive

Applicable Functions

Business Operation
Warehouse & Inventory Management

Use Cases

Inventory Management
Process Control & Optimization
Remote Asset Management

Services

Cloud Planning, Design & Implementation Services
System Integration

About The Customer

Creative Foam Corporation, founded in 1969, is a supplier of foam fabricating products to the automotive, medical, and composite industries. Based in Fenton, Michigan, the company serves customers across the Americas, Europe, and Asia. With over 600 employees, Creative Foam operates seven facilities located in Michigan, Indiana, Tennessee, and Colorado. The company has established itself as a key player in its industry, providing innovative solutions and maintaining a strong commitment to quality and customer satisfaction. Creative Foam's diverse product offerings and extensive reach make it a significant contributor to the sectors it serves, particularly in the automotive industry where precision and reliability are paramount.

The Challenge

For many years, Creative Foam Corporation used an AS400-based enterprise resource planning (ERP) system to manage operations. Although the system managed basic functions, it was not efficient in integrating and automating manufacturing processes, which are crucial for long-term success and growth of the company. The management team looked for a system that could seamlessly integrate data across the enterprise; provide more visibility and transparency into operations; and be cost effective.

The Solution

After a thorough search, Creative Foam Corporation’s management decided to replace its existing legacy system with Plex Cloud ERP for manufacturers. Plex is a cloud ERP/ Software as a Service (SaaS)-based system built specifically for the manufacturing enterprise. In less than a year, Plex was implemented and went live in all seven facilities at the same time. The benefits of cloud ERP were immediately apparent. 'Plex is so user-friendly that even some of our first-time computer users are able to handle the system with ease,' said Martin. From top-level executives to shop floor managers and production workers, all employees have quick and easy access to critical information.

Operational Impact

The company achieved 95 percent inventory accuracy by improving visibility and minimizing manual processes.
Six out of seven production plants went 100 percent paper-free, enhancing operational efficiency.
The company standardized OEE tracking procedures with the help of drilled-down reports, allowing for better equipment effectiveness monitoring.
Improved supplier communication through the Plex Supplier Portal, enabling paperless, real-time communication across the supply chain.

Quantitative Benefit

The physical inventory process, which previously required a day and a half's work for ten employees, can now be completed within a day with only a handful of employees.
Comprehensive inventory in all plants is now done once every six months, compared to once every quarter with the previous ERP system.