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Gemini Plastics, Inc. ERP Case Study

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Industry

Plastic

Challenge

Gemini Plastics faced operational inefficiencies due to reliance on spreadsheets and manual processes for managing production, inventory and job costing. Rapid business growth increased the complexity of their operations, creating an urgent need for more organized workflows, accurate and timely shop floor information and integrated data visibility across the business.

Results

By implementing Global Shop Solutions ERP, Gemini Plastics achieved automation and standardization of their production workflows, gained real-time insight into material usage and inventory and improved job costing accuracy. These advancements empowered the company to manage over 3,000 SKUs efficiently, optimize resource allocation and make informed sales decisions based on comprehensive, up-to-date data.

Key Applications

Inventory, Shop Floor Data Collection, Job Costing Accounting, Bill of Materials, BOM Compare, Estimating & Quoting, Sales, Shop Management, Tailored ERP

www.geminiplastics.net/
100%
Real-Time Cost Visibility
100%
PROCESS AUTOMATION
1
Centralized System

Seamless integration of data from all parts of the business is the backbone of any good ERP system. And that’s probably the #1 benefit of Global Shop Solutions. It puts all the data you need right at your fingertips so that everyone is working off the same page.

Bob Holbrook

Vice President of Sales and Marketing

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About Gemini Plastics

Founded in 1969 and based in Fallsington, Pennsylvania, Gemini Plastics is a family-owned custom injection molder of thermoplastics, specializing in make-to-order products for electronics, industrial, and commercial markets. The company operates a 40,000 sq. ft. facility with 23 molding machines and employs 70 production associates.

The Challenge

As Gemini Plastics, Inc. grew, the company struggled with inefficiencies caused by manual data entry and disparate spreadsheets. Managing over 3,000 SKUs for diverse markets, they needed a solution to provide reliable shop floor data, accurate bills of materials (BOMs) and consistent job costing. These gaps limited their ability to deliver on-time orders and maintain operational control in a fast-paced manufacturing environment.

The Solution

Recognizing the need for a unified system, Gemini Plastics evaluated ERP solutions that could address their operational complexity and growth ambitions. According to Bob Holbrook, Vice President of Sales and Marketing, "As the company continued to grow, we needed to get more organized. In particular, we needed to get more accurate information to the shop floor with regards to BOMs and routers so we could deliver orders on time. Global Shop Solutions had everything we were looking for in one integrated package." After selecting Global Shop Solutions ERP, Gemini Plastics digitized core manufacturing processes, automated inventory tracking and improved data access for the entire team. The integrated system enabled management and associates to work from a single source of truth, fostering accuracy and accountability across all departments.

The Results

Following the ERP implementation, Gemini Plastics saw measurable improvements in efficiency and insight. The company now tracks material consumption and labor costs at the job level with precision, directly supporting their ability to manage more than 3,000 SKUs and support 70 associates on the shop floor. Holbrook notes, "With Global Shop Solutions, we know the exact quantity of materials used on every job and how much they cost. We also can track our labor with remarkable precision. Moreover, the systems tracks all this in real time, so that as soon as we ship a job, we know the total costs." This real-time visibility extended to inventory and sales history, enabling leaner operations and faster, data-driven decision-making. With a robust and scalable ERP platform, Gemini Plastics continues to strengthen its market position and deliver customer value with confidence.

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