Case Study: American Axle achieves real-time operational visibility, 5-10% improved inventory turns and 5% higher manufacturing output with Plex Systems

Real-Time Data for Real-Time Decision-Making Across the Business

American Axle & Manufacturing (AAM), a global Tier 1 automotive supplier based in Detroit, needed real-time, consolidated operational and financial visibility across its Metal Forming Products Business Unit (MFPBU). Seven plants operated with different or no ERP systems, making it difficult for management to plan capacity, assure quality, and get a single source of truth for decision-making without disrupting production.

AAM partnered with Baker Tilly to roll out the Plex Smart Manufacturing Platform across all seven sites—cleansing and migrating data, integrating Plex with corporate Oracle/Hyperion, and delivering role-based training—while avoiding production downtime. The deployment delivered rapid ROI: inventory turns improved 5–10%, manufacturing output increased about 5%, scrappage fell, quality and compliance improved, planners can forecast on a 16-week window, and IT overhead was reduced.

American Axle

Michael Trathen

Senior Manager Lean Systems