Case Study: Thai Summit America achieves 70–112% throughput increase and 80% downtime reduction with Plex Systems

Thai Summit - Customer Case Study

Thai Summit, a global leader in sheet metal stamping based in Howell, Michigan, operates facilities in North America and Asia and has delivered over 1,000 new products across 35+ years. Facing labor shortages, paper- and Excel-based workflows, and limited visibility into downtime and micro-stoppages—while customers demanded more real-time reporting—Thai Summit needed a way to modernize operations and pinpoint production bottlenecks.

By deploying Plex’s MES Automation & Orchestration (MES A&O) in 2017, the company automated data capture, downtime detection, and reporting, empowering operators and enabling faster problem resolution. The results: roughly an 80% reduction in downtime (from 1.5 hours to ~20 minutes per 8-hour shift), mean time between failures rising to 40 minutes, throughput up 70–112% (40–50 → 85 jobs/hr), line revenue up 50% ($8K/hr → $12K/hr), and at least $3M/year saved from employee-driven improvements—now running across two facilities.

Thai Summit America

Janice D'Amico

Executive Business Systems & IT