auto manufacturing
Case Study

Tier 1 automotive supplier achieves integrated reporting and enhanced collaboration with the Plex Smart Manufacturing Platform

Read this case study to learn how a tier 1 automotive supplier achieves integrated reporting, enhanced collaboration and standardized processes across 20 locations globally with the implementation of the Plex Smart Manufacturing Platform.
auto manufacturing
Case Study

Tier 1 automotive supplier achieves integrated reporting and enhanced collaboration with the Plex Smart Manufacturing Platform

Read this case study to learn how a tier 1 automotive supplier achieves integrated reporting, enhanced collaboration and standardized processes across 20 locations globally with the implementation of the Plex Smart Manufacturing Platform.

Client background

A worldwide leader in the design, engineering, and manufacture of driveline, drivetrain and chassis systems and components for trucks, sport utility vehicles, passenger cars, and crossover vehicles. The company is a multi-billion dollar, Tier I supplier to the automotive industry.

The initial business challenge

The client, a $680M business unit representing the largest automotive forging enterprise in the world, required a leading, scalable, cloud-based ERP system to support their business operating requirements. Essential needs included heat management, yield optimization, inventory management, quality, traceability, SOX-compliant security, and shop floor controls.

The Baker Tilly approach

The client selected the Plex Smart Manufacturing Platform to replace their legacy ERP system. Baker Tilly lead the design and implementation of a common model across (5) locations, and integrated the solution into their overarching shared services architecture to support consolidated financials, corporate cash management, central accounts receivable, accounts payable and purchasing functions.

The business impact

The implementation of a common model across the enterprise, along with the integration of shared financial services allowed the client to achieve the following business results:

  • Significant inventory savings through tighter controls, and improved visibility and planning
  • More consistent product quality with embedded controls throughout the manufacturing process
  • Material yield optimization through deployment of Baker Tilly’s Material Performance Management functionality
  • Performance management reporting across the division’s manufacturing locations
  • Broad availability of information for enterprise-level reporting
  • Reduction in manual processes through process optimization and automation
  • SOX security compliance, including segregation of duties across users
  • Strict purchasing controls across the enterprise and improved supplier management
  • Central cash management and financial controls

A new set of challenges

Following a series of acquisitions across North America, Europe and Asia, our client needed the ability to quickly deploy the Plex solution to incorporate these new locations into the broader business unit. The variety of sites and their product lines presented a challenge to the Plex common model design and goal of deploying the solution with speed. Key to these deployments was the flexibility of the Plex solution, and ability to leverage the common model design in core business areas while quickly adapting to meet new business requirements including sintering, injection molding and tool manufacturing.

The Baker Tilly adapted approach

Over several years, the Baker Tilly team has successfully led the on-going deployments of the Plex common model across an additional (20) locations globally – with most locations converting from legacy systems to Plex in as little as 90 days. Baker Tilly’s rapid deployment approach leveraged our deep knowledge of the Plex solution, pre-defined templates from our Plex implementation toolset that accelerated activities, and our ability to quickly adapt the solution to meet the evolving requirements of the business.

On-going benefits

The on-going deployment of the Plex common model across the enterprise has allowed the client to achieve significant benefits from the Plex solution:

  • Single, common operating model across the business unit
  • Global, comprehensive enterprise-level reporting
  • Consolidation of multiple, standalone system and applications
  • Rapid deployment and scalability
  • End-to-end business processes performed within a single ERP system
  • Increased information availability
  • Enhanced collaboration
  • Integrated financial and tax reporting
  • Standardized processes enabling efficiency and automation
  • Tighter controls around inventory, purchasing, quality, and financials
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