Case Study: Ralco Industries achieves 60% scrap reduction, 15% less inventory, and 20% lower premium freight with Plex Systems

The Plex Manufacturing Cloud Revolutionizes Ralco Industries

Ralco Industries, an ISO/TS 16949‑certified tier‑one/two automotive supplier in Auburn Hills, MI, was struggling with fragmented systems—separate MRP, no PLC integration, and standalone shipping/receiving—which left inventory accuracy near 50%. That lack of visibility and inconsistent machine setups drove overstocking, high scrap, overtime, expedited shipments and general operational inefficiency.

Ralco implemented the Plex Manufacturing Cloud to unify MRP, PLC integration and shop‑floor functions with a web‑based, easy‑to‑use interface and “recipe” setup control. The change produced rapid results: scrap down 60%, inventory on hand down 15%, premium freight costs down 20%, training hours cut by more than 50%, plus reduced downtime and turnover and a payback in just over a year.

Ralco Industries

Jim Piper

President