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Mestex ERP Case Study

mestex-1

Industry

Make-to-Order

Challenge

Mestex faced significant operational limitations due to their legacy AS400 system, which provided minimal data accessibility and required expensive custom programming for even minor adjustments. This outdated infrastructure was unable to effectively support Mestex's intricate build-to-order manufacturing processes. Manual workflows dominated critical functions like inventory management, cost estimation and order processing, making it difficult to maintain accuracy, respond to customer demands or manage the complexities of thousands of product variations. As a result, Mestex struggled with inefficient resource allocation, high administrative overhead and limited ability to scale or optimize costs.

Results

By implementing Global Shop Solutions ERP, Mestex achieved enterprise-wide automation and real-time data visibility, resulting in a 50% reduction in inventory and the elimination of four senior clerical positions. The advanced custom configurator enhanced order accuracy and significantly streamlined the sales-to-production workflow. With over 100 employees and three production facilities, Mestex now benefits from precise cost estimation, improved inventory control and reduced general and administrative expenses. These results have enabled Mestex to operate with greater efficiency, agility and profitability in a competitive marketplace.

Key Applications

Inventory, Shop Floor Data Collection, Job Costing Accounting, Accounting, BOM Compare, HR & Payroll, Product Configurator

www.mestex.com/
50%
Reduction In Inventory
100%
Real-Time Visibility
4
Clerical Positions Eliminated

The configurator has made life much simpler for our sales team by simplifying the order entry process on both the front and back ends of the business. It makes order entry easier and more accurate because we don’t have to do any additional data entry to create the BOMs. Global Shop Solutions automatically does it for us.

Mike Cox

Inside Sales Manager

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About Mestex

Mestex is a Dallas-based leader in innovative HVAC solutions, serving diverse environments from industrial warehouses to labs and commercial kitchens. With over 100 employees and three production facilities, Mestex specializes in a wide range of heating and cooling products.

The Challenge

Mestex was constrained by an aging AS400 system that no longer met the requirements of their dynamic build-to-order environment. The lack of accessible, real-time data and dependence on costly programming for changes hampered operational efficiency. Manual processes made it challenging to accurately control inventory, estimate costs and manage the complexity of thousands of product configurations. These limitations resulted in inefficient use of resources, increased administrative workload and difficulty scaling production across three facilities.

The Solution

Seeking to modernize their operations, Mestex evaluated options and selected Global Shop Solutions ERP for its robust inventory management, real-time data integration and advanced custom configurator capabilities. The transition to Global Shop Solutions provided immediate visibility into inventory and shop floor activity, empowering managers to monitor production in real time. As Steven Hodgson, Division Controller at Mestex, noted, “The visibility of data within Global Shop Solutions definitely helped reduce our inventory.” Sales processes also improved dramatically with the configurator, as Inside Sales Manager Mike Cox shared: “The configurator has made life much simpler for our sales team by simplifying the order entry process on both the front and back ends of the business.” Operations Manager Ben McCarty emphasized the convenience brought by centralized data: “I’m in there all the time, reviewing job schedules, checking raw material usage and keeping track of everything that’s happening on the shop floor. Having all the data right at my fingertips is very convenient!”

The Results

After implementing Global Shop Solutions ERP, Mestex realized a 50% reduction in inventory and was able to eliminate four senior clerical positions - major cost savings that directly impacted the bottom line. The automation of critical processes reduced manual errors, enhanced order accuracy and enabled more strategic resource allocation. With over 100 employees and three production facilities, Mestex now leverages real-time data for superior inventory control and precise cost estimating. The company operates with increased efficiency, reduced administrative overhead and the agility to meet complex customer demands, positioning themselves for continued growth and innovation.

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