Case Study: Double H Plastics, Inc. achieves real-time manufacturing automation, 20% warehouse efficiency gain and major labor & error reductions with DELMIAworks

Improving Manufacturing Automation for Future Success

Double H Plastics, a longtime U.S. leader in plastic cores and insert-molded food packaging, faced growing pains as expansion into food packaging exposed limits of its legacy Unix/DOS “green screen” system. The company lacked real-time shop-floor visibility and enterprise integration, making scheduling, inventory movement and shipping error prevention difficult across multiple plants and short-cycle production lines.

Double H implemented IQMS (now DELMIAWORKS) EnterpriseIQ with RealTime Production Monitoring and worked with IQMS’ Automation Team to build RowHMI and RackTruck for shop‑floor data capture and optimized forklift/pick scheduling. The integrated solution (with nearly 1,200 wireless RealTime devices) eliminated third‑party interfaces, gave real‑time scheduling and tracking, improved warehouse movement efficiency by 20%, saved about $100,000/year in labor, removed paperwork and duplicate pulls, and virtually eliminated shipping errors, earning Double H a Progressive Manufacturing 100 award.

Double H Plastics, Inc

Frank Sica

Supply Chain Manager