Plex Systems > Case Studies > OKAY Industries Enhances Operations with Plex Cloud ERP for Precision Metalforming

OKAY Industries Enhances Operations with Plex Cloud ERP for Precision Metalforming

Customer Company Size

Mid-size Company

Region

America

Country

Mexico

Product

Plex Cloud ERP

Tech Stack

Cloud ERP

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Customer Satisfaction
Digital Expertise

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)

Applicable Industries

Metals
Automotive

Applicable Functions

Business Operation
Quality Assurance

Use Cases

Factory Operations Visibility & Intelligence
Predictive Maintenance

Services

System Integration

About The Customer

OKAY Industries, Inc. is a company specializing in stamping, machining, and prototyping, with a focus on producing complex metal stampings with extremely tight tolerances. The company serves a diverse range of industries, including medical and surgical devices, defense, firearms, specialty, industrial, and automotive markets. Known for its precision and commitment to perfection, OKAY Industries operates in a highly demanding environment where there is no room for error. The company is located in Queretaro, Mexico, and is recognized for its culture of continuous improvement, having achieved ISO certification and compliance with new ISO standards. OKAY Industries is dedicated to maintaining high standards of quality and efficiency in its operations.

The Challenge

OKAY Industries faced a significant challenge in managing its operations due to the existence of 18 different databases that were not integrated with the company's UNIX server. This fragmentation made it difficult to compile detailed information necessary for continuous improvement in operational efficiency. The company needed a solution that could integrate its entire operation, streamline data management, and support its culture of continuous improvement. Additionally, OKAY Industries had to comply with new ISO standards and requirements, which added another layer of complexity to its operations.

The Solution

OKAY Industries implemented Plex Cloud ERP to address its operational challenges. The implementation began with a focus on quality functions, as the company's parts require perfection. The system was customized to track weights up to seven decimal places, ensuring precise quality monitoring. The transition to Plex Cloud ERP involved inputting extensive data, including part numbers and routings, which was initially done by student interns. Once the data was in place, the company used Plex for quality monitoring, which went smoothly. The next phase involved implementing a complex costing system within Plex, allowing OKAY to analyze the cost of producing each part down to the penny. This system provided detailed information on material costs, assembly costs, and manpower, enabling managers to drill down into the data for insights. The implementation was successful, with a dedicated team ensuring internal buy-in and setting a firm go-live date. The result was a smoothly functioning operation with 100% real-time data, enhancing production visibility and decision-making.

Operational Impact

OKAY Industries streamlined its operations by replacing 18 databases with Plex Cloud ERP, improving data management and reporting.
The company achieved a 2% increase in press efficiency each quarter following the implementation of the new system.
Efficiencies gained from the system allowed OKAY to manage double-digit annual growth without the need for additional staff.
Access to real-time information through Plex Cloud ERP eliminated part shortages, identified production problems, and improved decision-making.
Prospective customers visiting the plant are impressed by the production systems and the accessibility of information, enhancing OKAY's reputation.

Quantitative Benefit