Case Study: Plastic Components, Inc. achieves lights-out automated manufacturing and 10x sales growth with DELMIAworks

IQMS Helps Plastic Components, Inc. Set the Leading Edge of Automated Manufacturing

Plastic Components, Inc. (PCI) is a Germantown, Wisconsin injection molder known for patented "lights‑out" automated facilities. Despite running highly automated production, PCI relied on Excel, Access and handwritten notes and lacked reliable production scheduling, inventory control and true part costing, which constrained scalability and decision-making.

After a nine‑month implementation of IQMS EnterpriseIQ ERP with RealTime Production Monitoring and EDI, PCI centralized order flow, automated scheduling and achieved second‑by‑second machine visibility—enabling one person to manage 60 machines and consolidate multiple roles. The system delivered 10× revenue growth (from $3M to $30M), 60 fully automated cells running 24/7, clearer part profitability, tighter capital allocation and significantly more efficient use of resources.

Plastic Components, Inc.

Tom Duffy

President & Owner