Case Study: Advanced Vehicle Assemblies achieves real-time production visibility and inventory control with Plex Systems

Advanced Vehicle Assemblies Utilizes Plex for Increased Production Visibility & Control

Advanced Vehicle Assemblies (AVA), an automotive metal‑forming and joining specialist based in Milan, MI with four sites and more than 500 employees, needed to replace an aging ERP after splitting from a sister company in 2020. The legacy system required heavy maintenance, lacked MES integration, and forced manual processes that prevented real‑time production reporting and reliable inventory tracking — prompting an urgent, 60‑day go‑live timeline for a new solution.

AVA selected the cloud‑based Plex platform and completed the Milan implementation on schedule with dedicated Plex support and focused data cleansing and training. The result was immediate: real‑time production reporting and inventory visibility, native KPIs, elimination of financial consolidation software, faster shop‑floor problem resolution, and the ability to roll out subsequent plants with minimal external assistance while maintaining lean operations.

Advanced Vehicle Assemblies

Rob Arrowsmith

Chief Information Officer