| COMPANY: | Ralco Industries |
| HEADQUARTERS: | Auburn Hills, MI |
| SIZE OF COMPANY: | $10M-$25M in revenue |
| INDUSTRY: | Automotive supplier |
| PRIMARY PRODUCT LINE: | Metal stamping and welded assembly; exhaust, steering, chassis, suspension, seating, HVAC subassemblies |
| NAME OF PROJECT: | Initiative Drives Improved Quality, Delivery, Cost |
| PROJECT OBJECTIVE: | To improve setup time, traceability, inventory control, and OEE by integrating shop floor processes and systems; reduce downtime; improve run rates and quality |
| TECHNOLOGIES EMPLOYED: | Plex Online from Plex Systems, Allen-Bradley PLC PleXML, Rockwell Automation RSView and RSLinx |
| ACCOMPLISHMENTS/ROI: | Improved quality by 635 ppm to .16 ppm; on-time delivery went from 87% to 100%; inventory accuracy rose from below 50% to 99.9%; OEE improved from 28% to 60%; reallocated 50% of operator training to more highly skilled course content; cut premium freight costs 20%; reduced scrap 60%; payback in just over a year |