Case Study: Tuffaloy closes the execution gap with MachineMetrics

Tuffaloy cuts inventory corrections 85% with MachineMetrics

Tuffaloy, a manufacturer of resistance welding components, faced a significant execution gap between its Epicor Kinetic ERP system and its actual shop floor operations. This disconnect resulted in outdated production standards, a lack of visibility into labor and downtime causes, and blind spots during off-shift production. To address this, Tuffaloy partnered with vendor MachineMetrics to integrate real-time machine data with their ERP.

The solution implemented by MachineMetrics provided real-time data collection and bidirectional integration with Epicor. This enabled Tuffaloy to update cycle time standards based on actual performance, automatically classify and quantify downtime, and gain live visibility into production. The results included an 85% reduction in inventory corrections, reclaiming 10 hours per machine per month from a manual process, and achieving a 30-minute response time for quality issues. MachineMetrics' platform closed the data loop, transforming operations and supporting a cultural shift towards data-driven decision making.

Tuffaloy