Plex Systems > Case Studies > Ralco Industries’ Next-Generation Approach to ERP in Automotive Manufacturing

Ralco Industries’ Next-Generation Approach to ERP in Automotive Manufacturing

Customer Company Size

Mid-size Company

Region

America

Country

United States

Product

Plex Manufacturing Cloud

Tech Stack

Cloud ERP

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Customer Satisfaction
Digital Expertise
Productivity Improvements

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)
Infrastructure as a Service (IaaS) - Cloud Computing

Applicable Industries

Automotive

Applicable Functions

Discrete Manufacturing
Quality Assurance

Use Cases

Factory Operations Visibility & Intelligence
Manufacturing System Automation
Predictive Maintenance

Services

Cloud Planning, Design & Implementation Services
System Integration

About The Customer

Ralco Industries, Inc., based in Auburn Hills, is a tier 2 automotive supplier that has been operating since 1970. The company specializes in the design, prototyping, production, and distribution of high-tolerance metal stampings and welded assemblies. Ralco is known for setting a high standard of product and process quality in the industry, achieving a defect rate of less than one part-per-million for eight consecutive years. This achievement is a testament to the company's commitment to continuous innovation and improvement in its operations. Ralco's management has prioritized fostering a culture of quality, providing personnel with the resources needed to drive improvements. Over the years, the company has invested significant time and capital in maturing its process capabilities and adopting next-generation ERP solutions to enhance its operations.

The Challenge

Ralco Industries, a tier 2 automotive supplier, has been committed to maintaining a high standard of quality in its products and processes since its inception. The company has achieved a defect rate of less than one part-per-million for eight consecutive years, which requires continuous innovation and improvement in people, processes, and technology. As the company matured its process capabilities, it recognized the need for a next-generation ERP solution to support its quality-centric culture. The challenge was to find a solution that would enable operators and leaders to take responsibility for the quality and success of processes, allowing them to make necessary improvements. In 2001, Ralco chose the Plex Manufacturing Cloud as its ERP solution, recognizing the potential of cloud technology to stay ahead of the competition.

The Solution

Ralco Industries implemented the Plex Manufacturing Cloud as its ERP solution in 2001, taking a progressive approach to its ERP implementation. The company recognized the potential of cloud technology to stay ahead of the competition and chose Plex Systems for its comprehensive and integrated platform. The solution supports nearly all aspects of Ralco's operations, from sales to purchasing, inventory, production, HR, training, reporting, and customer complaints. Ralco has also been working towards developing a 'smart' manufacturing environment by integrating its equipment and machinery with the Plex Systems solution. The integrated platform provides superior control over operations, ensuring operators meet training requirements, enabling serialized traceability, and offering minute-by-minute performance indicators. The system's holistic nature allows for remote interaction with equipment and streamlines alerts for corrective actions, fostering a proactive approach to quality and continuous improvement.

Operational Impact

Ralco's integration with Plex Systems has driven unprecedented visibility into its operations, aiding the customer success team and driving follow-on business.
The system's tight integration on the shop floor has been crucial for Ralco's excellence in quality management, streamlining alerts for corrective actions.
The digitization of data and records has enabled Ralco to generate quality reports on demand, demonstrating control and diffusing blame in client meetings.
Ralco's holistic system deployment has freed personnel to focus on adding value rather than manual quality checks, enhancing overall operational efficiency.
The company's proactive approach to quality and continuous improvement has been supported by the integrated platform, ensuring superior control over operations.

Quantitative Benefit

Ralco has achieved a defect rate of less than one part-per-million for eight consecutive years.
The company turns its inventory more than 250 times per year, indicating high operational efficiency.