Advanced Plastiform, Inc. ERP Case Study

Industry

Plastic

Challenge

Advanced Plastiform encountered significant operational challenges as its legacy ERP system could not keep pace with the company’s rapid expansion and the complexity introduced by multiple facilities and diverse product lines. The reliance on manual, paper-based workflows made inventory tracking cumbersome, limited visibility into labor and material costs and hampered timely decision-making. These constraints increased operational costs and restricted the company’s ability to respond effectively to customer demands and market changes.

Results

By implementing Global Shop Solutions ERP, Advanced Plastiform achieved substantial improvements in manufacturing efficiency and cost management. Real-time inventory tracking across all facilities improved visibility and control, while electronic data interchange (EDI) eliminated manual order entry and reduced administrative costs. Automation of core processes, detailed cost tracking and a paperless environment led to measurable gains in logistics efficiency, faster response times and significant annual savings.

Key Applications

Inventory, Advanced Planning and Scheduling (APS), Shop Floor Data Collection, Job Costing Accounting, Accounting, EDI, Paperless

advancedplastiform.com/

100%

Increased Logistics Efficiency

100%

Paperless shop floor

$50K

Savings

FULL

Data Visibility

With Global Shop Solutions, our planners can easily see where we have the capacity to slide in some of the kanban jobs without disrupting workflow. This makes us more efficient and allows us to provide better customer service by always having enough inventory on hand.

Jay Jolly

Owner

About your Customer

Advanced Plastiform is a North Carolina-based manufacturer specializing in custom plastic molding and fabrication services, including thermoforming, injection molding, CNC routing, secondary assembly and finishing, serving industries such as automotive, medical, transportation and telecommunications from three large facilities.

The Challenge

Advanced Plastiform was experiencing operational bottlenecks due to an outdated ERP system that struggled to support its expanding manufacturing footprint and growing customer base. Manual processes and paper-based documentation made it increasingly difficult to track inventory, manage logistics, and understand true production costs. As Co-Owner Jay Jolly shared, "Our old system worked well when we had one machine and 10 customers. But as we grew, its limitations became more and more of a constraint." These inefficiencies threatened productivity and the company’s ability to meet evolving customer demands.

The Solution

Seeking a robust, integrated manufacturing ERP solution, Advanced Plastiform evaluated several systems before selecting Global Shop Solutions for its real-time inventory tracking, comprehensive EDI capabilities and strong reputation among current users. According to Jay Jolly, "We chose Global Shop Solutions based on referrals from current users, its real-time inventory tracking capabilities and the in-depth training for new users." The implementation enabled the company to digitize workflows, automate purchasing and achieve real-time visibility into over 4,000 inventory items across three facilities and all items in transit. The transition to a paperless system ensured that all employees accessed accurate, up-to-date information, driving consistency and accountability throughout the organization: "The best thing about going paperless is that it forces everyone to use the system. As a result, everyone has the information they need at their fingertips. And it’s instantly available rather than hidden away in some file or somewhere out on the floor."

The Results

Global Shop Solutions ERP delivered measurable operational benefits for Advanced Plastiform. Annual EDI savings reached $50,000, and the company doubled its logistics efficiency. The transition to automated order entry reduced related costs by over 60%, while detailed item cost tracking ensured competitiveness on every order. Jolly highlighted, "We used to spend hours looking for tooling; now we find it in minutes. EDI has reduced our cost of order entry by over 60%, and has eliminated the cost of submitting order shipment information. Knowing our true item costs allows us to insure we’re competitive on every item, not just on a blanket program." With 250,000 square feet of manufacturing space now fully integrated, Advanced Plastiform benefits from faster decision-making, lower administrative overhead and a scalable platform to support continued growth.