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BHI Solutions ERP Case Study

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Industry

Metal Fabrication

Challenge

BHI Solutions faced significant operational complexity managing two manufacturing plants across the U.S. and Mexico. Manual processes created data silos, made information retrieval slow and hindered the ability to accurately track parts, labor and inventory between locations. This fragmentation impacted purchasing, scheduling and production efficiency, limiting their ability to make data-driven decisions across all departments.

Results

By implementing Global Shop Solutions ERP, BHI Solutions brought both facilities under a single, integrated system. This enabled electronic data collection on the shop floor, centralized document control and real-time access to production data. The result was a dramatic reduction in manual tasks, improved cross-plant coordination and the ability to manage purchasing, scheduling and job tracking for both locations from one system. These improvements empowered better decision-making, faster information access and measurable gains in productivity and efficiency.

Key Applications

Inventory, Advanced Planning & Scheduling, Shop Floor Data Collection, Document Control, Order Management, Tailored ERP

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We’ve also implemented the Document Control feature, which has proved to be another real time saver. We used to make copies of all our material certifications as the materials came in. Recently, we scanned all those certifications and created a directory for them so that all the information is in Global Shop Solutions. Now when materials come in, we use Document Control to automatically link them to the right certifications.

Pete Madrid

Production Manager

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About BHI Solutions

BHI Solutions is a recognized leader in metal forming, manufacturing springs, stampings, wire forms and slide products for industries including auto, aerospace, defense, electronics, medical hardware and telecommunications. With over 100 employees, BHI operates two plants in Garden Grove, California and Tijuana, Mexico and is ISO 9001:2008 registered and AS9100 certified. 

The Challenge

BHI Solutions, a leader in metal forming and ISO 9001:2008 certification, operates two manufacturing plants in Garden Grove, California and Tijuana, Mexico. With over 100 employees, they serve industries ranging from aerospace to medical hardware. Managing operations across two countries introduced high levels of complexity - manual systems led to fragmented data, duplicated efforts and inconsistent information across departments. Tracking parts, labor and orders between locations was time-consuming, and accessing up-to-date production or inventory information was a challenge. These issues hindered operational efficiency and made it difficult to maintain the high standards required by their diverse customer base.

The Solution

BHI Solutions identified the need for a robust ERP solution to unify their manufacturing processes and eliminate operational silos. After considering their requirements for data accessibility, real-time visibility and multi-plant coordination, they chose Global Shop Solutions ERP software. The platform's advanced planning and scheduling, shop floor data collection and document control capabilities were key differentiators. According to Pete Madrid, Production Manager, "The ease of navigation throughout the system, the ability to go into different areas and get information quickly - that’s where Global Shop Solutions has really simplified things for us. And not just on the shop floor, but in every department." The ERP system enabled BHI Solutions to centralize purchasing, manage production schedules across both plants and ensure all staff - from engineering to sales - could access accurate, real-time data regardless of location.

The Results

With Global Shop Solutions ERP, BHI Solutions unified the management of both plants, delivering immediate gains in operational efficiency. Electronic shop floor data collection and centralized document control eliminated manual entry and reduced errors. All purchasing, production scheduling and job tracking for both facilities moved to a single interface, supporting data-driven decisions and faster response times. Pete Madrid notes, "We basically run the business out of our U.S. plant. Our engineering support team, salespeople and administrative staff all work out of the U.S plant. We do all the purchasing for both plants here in the U.S. And when a customer calls to place an order, the phone rings here in Garden Grove, regardless of whether they’re calling from Mexico or the U.S." The ERP’s ongoing enhancements also empower continuous improvement: "Every time someone shows their desktop on a Friday Feature, I see buttons and features I’ve never seen before. So I quickly try to figure out how they got that button and how we can use that feature in our business." Today, BHI Solutions is positioned for growth with a unified, data-driven approach to manufacturing management, supported by measurable improvements in productivity and cross-plant collaboration.

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