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Solar Spring & Wire Forms ERP Case Study

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Industry

Make-to-Stock

Challenge

Solar Spring, operating a large-scale manufacturing facility with over 170 machines and serving demanding automotive and industrial clients, faced persistent obstacles in maintaining efficient production scheduling, accurate inventory management and comprehensive materials tracking. Manual processes and disparate data sources created bottlenecks, reducing their ability to quickly respond to customer requirements and resulting in an on-time delivery rate stagnating around 88%. As the business expanded, the need for a unified, real-time ERP solution became critical to support data-driven decisions and scalable growth.

Results

By implementing Global Shop Solutions ERP software, Solar Spring transformed its manufacturing operations with real-time data visibility, automated inventory management and integrated shop floor tracking. This robust solution enabled the company to increase its on-time delivery rate to 96%, optimize productivity across its 80,000 sq. ft. facility, and empower leadership with instant access to actionable performance metrics. The result was enhanced customer satisfaction, reduced delays and a more agile, competitive business.

Key Applications

Inventory, Shop Floor Data Collection, Document Control, Paperless

www.solarspring.com/
96%
On-Time Delivery Rate
170+
Active Machines
1
Centralized System

Global Shop Solutions has helped Solar Spring become successful because they understand that the industry we are in is a constantly changing industry. What Global Shop Solutions has done is provide innovations in manufacturing software that we at Solar Spring can use to keep us ahead of our competition in the industry.

Emilio Ortega

Quality Director

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About Solar Spring

Solar Spring is a manufacturer of springs, stampings and wire forms serving major clients in the automotive and industrial sectors. Founded in 1979, the company operates out of an 80,000 sq. ft. facility in Elk Grove Village, Illinois and has grown from a small garage business to a large, minority-owned enterprise.

The Challenge

Solar Spring experienced significant challenges as it grew from a garage-based startup to a major player in the automotive and industrial sectors. With a facility spanning 80,000 sq. ft. and more than 170 machines in operation, the company struggled to maintain efficient scheduling, inventory accuracy and rapid materials tracking. Disconnected systems and manual data entry led to inefficiencies, delayed production responses and a previous on-time delivery rate hovering around 88%. As customer demands and production complexity increased, Solar Spring identified the urgent need for a unified, data-driven approach to manage its manufacturing processes.

The Solution

After evaluating several ERP software options, Solar Spring selected Global Shop Solutions for its comprehensive, integrated platform and strong partnership approach. Emilio Ortega, Quality Director & ERP Implementation Director, highlighted the collaborative relationship: “We had looked at several other ERP software, but they were very difficult to communicate with... We needed to feel that we were linked in a partnership with them. This is something we consistently experienced with the people at Global Shop Solutions.” The company quickly leveraged Global Shop Solutions’ real-time data, inventory automation and shop floor tracking to eliminate manual bottlenecks and enable automated purchasing and document control. Ortega noted the pace of innovation: “Global Shop Solutions is always a step ahead of us. We’re always trying to catch up with all of their innovations and updates.”

The Results

Implementing Global Shop Solutions ERP software delivered measurable gains for Solar Spring. Automated workflows and integrated data visibility enabled management to make instant, informed decisions while shop floor tracking and inventory control improved operational accuracy. Most notably, the on-time delivery rate rose from the high 80s to 96%. Emilio Ortega confirmed the impact: “Global Shop Solutions has really helped us in terms of on-time delivery. We’re now at about 96% compared to only the high 80s before Global Shop Solutions.” With enhanced productivity across more than 170 machines in the 80,000 sq. ft. facility, Solar Spring can now adapt quickly to changing industry demands.

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