Case Study: NHK Spring Precision of America achieves error-proof shipping and improved quality controls with Plex Systems

Plex and IGear Bring Automotive Supplier Improved Quality Controls

NHK Spring Precision of America, a North American automotive spring supplier using Plex Cloud ERP, faced costly risks from human packing errors: wrong spring types, misaligned parts, or incorrect spacing could halt an OEM assembly line and damage customer relationships. Temporary fixes—outside quality inspectors and extra internal checks—were expensive and still left the process vulnerable to mistakes.

IGear built a vision inspection system integrated with Plex via web services to validate machine setup, inspect paint color, spacing and part counts, and require a successful remote transaction before a tray is released. The system alerts operators via an HMI, stores images for dispute resolution, averages under two seconds per Plex round trip, eliminated external QC inspectors, and delivered reliable, error-proofed shipments that cut costs and ensured compliance with the OEM’s strict requirements.

NHK Spring Precision of America

Hideki Katsu

Vice President