Case Study: Ultra Tool & Manufacturing, Inc achieves $128K in annual savings and 243 labor hours reclaimed with Plex Systems

Ultra Tool & Manufacturing, Inc - Customer Case Study

Ultra Tool & Manufacturing is a 54‑year‑old, Germantown, Wisconsin–based precision metal stamping and fabrication shop with just over 100 employees serving automotive, RV, electrical, lawn & garden, small engine and defense markets. Although Ultra had used Plex ERP/MES, they lacked granular plant‑floor visibility and automation, which caused manual errors, unknown machine and operator rates, excess setup time and more than 240 hours of extra annual labor.

Beginning in June 2021 Ultra deployed Plex MES Automation & Orchestration in a phased rollout—starting with one stamping press and expanding to ten—to automate production recording, label‑making and machine data collection. The solution delivered real‑time machine/operator rates, streamlined workflows and targeted training, producing immediate savings: about $48K/year from automating production recording and labels, $80K/year from reduced setup time, and roughly 243 manual labor hours saved, paying for the investment quickly.

Ultra Tool & Manufacturing, Inc

Andrew Loescher

Automation Specialist