Engine transmission gears
Case Study

Engine manufacturer increases production with cloud ERP software

Engine transmission gears
Case Study

Engine manufacturer increases production with cloud ERP software

This Baker Tilly and Plex Systems client (the Company) is the leading engine supplier to a global heavy equipment manufacturer.

When the Company built its newest facility, Plex Online was the chosen solution. Their decision was based on first-hand experience having years of success using Plex Online in the Company’s other operations.

The business challenge

During implementation at the new facility, the Company encountered difficulty ramping up production in its new state-of-the art assembly plant. Plex Systems called in Baker Tilly to help support the final stages of the Plex Online implementation and to provide on-site manufacturing ERP insight. The Company welcomed Baker Tilly’s expertise in operational process, training, and documentation support. The Company’s Plex Online implementation included many new functional enhancements, which presented unique challenges to both the Plex Systems project team and the Company’s management.

The Baker Tilly solution

The consulting specialists at Baker Tilly conducted a thorough situation analysis and then helped the client enhance and execute its implementation strategy. This work included:

  • Assisting the project team with all business process and Plex Online related information gathering requirements
  • Developing standard operating procedures
  • Assisting with the creation of training documentation to promote process standardization within the facility
  • Analyzing the material flow process
  • Assessing warehousing processes and line-side replenishment methods
  • Consulting with floor level personnel in receiving, warehousing, materials delivery, and other specified areas to mitigate process issues related to inventory flows

Business results

During the project, Baker Tilly supported the Company and helped its leadership team meet project implementation and production goals using the Plex Online solution. Specifically, Baker Tilly was able to provide value to the business in the areas of:

  • Developing process documentation of Plex Online best practices and tactical how-to guides for various functional areas. This included definition of clear processes and creation of documentation to standardize the following:
  • Reviewing and refining level two and three process documentation for the Quality department to meet ISO requirements.
  • Creating management reporting training documentation designed to guide new employees in the best utilization of Plex Online
  • Evaluating material and logistical processes and resolving line-side inventory discrepancies, which helped contribute to an 80% reduction in out-of-process inventory deliveries
  • Finalizing the implementation of training lessons at the work center level to provide floor personnel with operational best practices
  • Providing recommendations on the best use of customer returns for products re-entering the facility
  • Helping design a training program for current and future employees that employed best practices to maximize consistency between actual processing of inventory and Plex Online inventory positions throughout the plant
  • Subassembly reintroduction process
  • Product disassembly and repair process
  • Inventory serialization process for large, high value components
  • Inventory reconciliation process at work center locations
  • Resolution of insufficient source material issues at production stations
  • Validation during the scanning and loading of finished engine customer shipments to the freight forwarder
  • Crankshaft handling and loading process
  • Over 100 other related work instructions in materials, engineering, non-conforming materials, production, quality, management reporting, and shipping/receiving

Baker Tilly offers a specialized consulting team with deep vertical knowledge and exceptional Plex Online implementation and optimization skills. The firm’s consulting practice applies best practice methodologies to organizational needs and successfully implements Software as a Service (SaaS) business solutions. Baker Tilly helps take out the complexity and risk of challenging software deployments.

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