Case Study: United Southern Industries, Inc. achieves 80% inventory variance reduction and eliminates monthly manual counts with DELMIAworks

EnterpriseIQ ERP Solution is Cornerstone of Success for Top Molder

United Southern Industries, a North Carolina-based injection molder, faced rising foreign competition and outdated, manual ERP processes that undermined its shift to a lean, open‑book culture. Monthly physical inventories took days to count and weeks to reconcile, variances reached as much as $100,000, and shop‑floor data (scrap, BOMs, machine stats) wasn’t reflected in scheduling or accounting, limiting visibility and decision-making across the company.

United Southern implemented IQMS EnterpriseIQ, a single‑database ERP with modules for inventory tracking, finite scheduling, realtime production monitoring, wireless WMS and an EDI translator. The system eliminated monthly manual counts, cut inventory variances by as much as 80% (end‑of‑year counts now take about three hours with variances as low as $2,000 on $28M sales), saved more than 10 work hours per week on EDI, improved machine utilization and cash flow, enabled 24/7 customer service, and helped drive labor and manufacturing costs below industry averages.