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Plastic Components Inc

Delivering leaner and faster manufacturing operations with lower raw material costs

DELMIAWorks helps Plastic Components Inc (PCI) increase traceability for ISO compliance
Plastic Components Inc Case Study Featured Image showing two factory workers discussing optimised manufacturing processes at machine
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About Plastic Components Inc

Powering 60+ machines with fully automated lights out manufacturing 24/7

Specialists in automated manufacturing since 1989, Plastic Components, Inc (PCI), manufacturers critical injection moulded thermoplastic parts for original equipment manufacturers (OEMs).
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Getting a handle on true manufacturing costs

Excel spreadsheets, paper and Access databases meant PCI couldn’t manage production & costs.
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Scheduling 60+ machines with 1 person

Automating processes has meant PCI has been able to consolidate production scheduling to one role.
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Production matched to customer demand

Has helped deliver greater efficiency, reduce lead times and deliver more efficiently.
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"PCI has experienced strong growth as a low-cost, at-home injection moulder, but our multi-database system was hindering growth. For us, it all boiled down to having better control of our critical business data. We wanted a single-database solution that offered centralised, accurate, and relevant data that was accessible to everyone in our company. In other words, we wanted a system that was in line with our vision for success."
Plastic Components Inc
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Manufacturing round the clock

Unconnected and siloed data hindering growth & increasing pressure on 24/7/365 operation

With over 78,000 square feet of manufacturing space across two facilities, PCI’s moulding machines produce parts on a fully automated basis 24 hours a day – every day of the year. However, a mix of Excel and unconnected systems were significantly hindering their growth with staff resources put under considerable pressure as business-critical data was scattered across the organisation.
Two workers discussing on the factory shop floor as machines continue to produce goods round the clock
Competing on a global stage

Lean manufacturing, total process automation and investment in equipment & system enables PCI to grow

Faced with an increasingly competitive global market, PCI took an innovative approach with complete process automation to keep costs low and quality high. This approach has enabled PCI to prosper as a supplier of critical moulded plastic parts for a diverse range of OEMs – shipping over 25 million parts per month.
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Single database manufacturing ERP

Fully-automated, lights out, next-generation manufacturing running without operators

Running such a unique system requires detailed and timely data. PCI relies on DELMIAWorks to manage almost every aspect of their business. Everybody in the organisation can access reliable performance data to drive improvements and operate leaner and faster with less investment in up front raw materials and a 25% reduction in warehouse space.
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"Our company relies on automation to wring out all waste in the manufacturing process, DELMIAWorks lets us apply that same high level of excellence to the management of our business. We can now monitor and assess all manufacturing operations as they happen in real-time. We’re also better able to communicate accurately amongst ourselves and with our customers and suppliers. DELMIAWORKS gives us the ability to focus on what we do best. We know our profitability down to the part. DELMIAWorks allows us to know on a second-by-second basis the status of all the machines that are running in both facilities."
Plastic Components Inc
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