Moldtech improves efficiency and reduces scrap with unified MES and ERP platform

Moldtech, a manufacturer of rubber molded products, faced increasing operational challenges as it scaled its production over time. The company relied on a mix of legacy systems, spreadsheets and standalone tools to manage production, inventory and reporting.

This fragmented setup resulted in delayed and inaccurate reporting, limited plant floor visibility and near-zero inventory accuracy. Access to reliable, real-time data was restricted, making it difficult to control materials, track finished goods and calculate production costs accurately.

To support growth and improve quality, Moldtech required a unified platform that could connect business systems with shop-floor operations and provide consistent, trustworthy data.

Implementing a unified smart manufacturing platform
After evaluating multiple solutions, Moldtech selected the Plex Smart Manufacturing Platform from Rockwell Automation. The implementation combined enterprise resource planning (ERP), manufacturing execution system (MES), quality management system (QMS) and MES automation capabilities into a single integrated environment.

The goal was to replace disconnected tools with a centralised system providing real-time inventory levels, live production metrics and accurate costing data.

The implementation followed a collaborative approach, with internal teams leading deployment in their respective areas. Despite organisational restructuring during the rollout, the transition was completed in approximately six months, with new employees trained directly within the system.

Real-time visibility improves decision-making
With the new platform in place, Moldtech gained real-time visibility into production performance and scrap levels. Data that previously required manual compilation is now automatically generated and accessible across the organisation.

Weekly reporting processes have been streamlined, with scrap trends, cost impacts and performance metrics available directly from the system. This transparency has improved decision-making and aligned teams around measurable performance indicators.

Measurable improvements in cost and efficiency
The implementation delivered clear operational and financial results:

Real-time scrap reporting allows Moldtech to assess the financial impact of production losses immediately, supporting more effective corrective actions.

Strengthening financial accuracy and planning
In addition to operational improvements, the platform enhanced financial visibility. Transactions and cost data are now accessible in real time, enabling more accurate forecasting and planning.

During the first quarter of 2025, Moldtech reported sales of approximately $4 million, with projected financial results within $2,500 of actual figures. This level of accuracy reflects improved control over costs and margins.

Supporting scalability and continuous improvement
By replacing disparate systems with a unified digital platform, Moldtech has established a scalable foundation for future growth. The integration of ERP, MES and quality management functions supports consistent processes across the organisation and reduces reliance on manual workarounds.

The case demonstrates how adopting a unified smart manufacturing platform can improve data reliability, reduce waste and enhance operational efficiency, while enabling manufacturers to scale with greater confidence and control.

Edited by Romila DSilva, Induportals Editor, with AI assistance.