Early in the process, Somic tapped outside consulting to assess several key initiatives. This exercise led to a strong recommendation to replace and modernize their existing, disconnected and antiquated systems. Somic dug deep into its processes and detailed the many areas of improvement which are possible with modern, integrated ERP and MES platforms. Three major pillars came to light in the process. First, disconnected systems produced disconnected data, which was difficult to collect and analyze. Secondly, technology for production control was not optimized. And finally, an actionable, fully integrated quality management solution was missing.
After discovering that its data was not trustworthy, Somic went even deeper to realize that data aggregation was both burdensome and labor intensive. This led to inefficient planning and scheduling, and a lack of visibility to work-in-progress inventory. These factors, among others, gave way to selecting Plex, by Rockwell Automation, to realize benefits across multiple workstreams: order to cash, procure to pay, production scheduling, asset management & maintenance, automated data collection, quality management, inbound and outbound electronic data interchange (EDI), and accurate deliveries to customers.
With its established presence in the automotive supply chain, and its ability to offer world-class application solutions in the cloud, Plex is providing Somic with a connected plant floor, digital production tracking, and real-time dashboards which will support Somic’s initiatives for growth and efficiency.
“The choice to select Plex, by Rockwell Automation came at the perfect time in our modernization journey,” said Frank Alley, vice president, finance & administration, Somic America, Inc. “We are so pleased that we decided to audit and understand our existing systems first. This gave us the best information on what we need for our future state. Then, the real drivers for selection are the anticipated benefits of utilizing Plex’s end-to-end ERP and manufacturing solutions, across a single, connected database and a common user experience for our associates. We are looking forward to partnering with Plex, as we embark on our digital transformation journey.”
“From the Plex side, my team was given unfettered access across several functional departments at Somic; to delve deep into current processes and future needs,” said Jim Webster, account manager, Plex, by Rockwell Automation. “When we spoke with Somic and found out where we could move the needle, the benefits of our smart manufacturing suite took center stage as we demonstrated a strong case for change through efficiency gains and access to real-time information.”
While establishing a platform for growth at Somic America, Plex, by Rockwell Automation provides the following benefits to its manufacturing customers:
- Single, modern enterprise resource planning (ERP), manufacturing execution systems (MES), quality management systems (QMS) and electronic data interchange (EDI) platforms
- Connectivity to machines on the plant floor, producing real-time data
- Streamlined production planning and scheduling
- Robust inventory planning and visibility
- End-to-end product traceability and genealogy
- Clear visuals from dashboards providing instant and accurate feedback
- Automating tasks, preventing errors, enforcing discipline
- Full program and project accounting
- Supplier performance, order management and chargebacks in a single system
- Centralized and flexible labeling system
- Digital platform to plan and execute operator training
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