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A purpose-built automotive MES solution offering integrated APQP/PPAP digitization, real-time traceability from materials to shipping, and IoT-enabled predictive maintenance to accelerate compliance, contain quality issues rapidly, and optimize production efficiency.
23 Dec 2025 | 2159 Views | By Autocar Pro Branding Feature
"Plex provides real-time genealogy tracking, allowing manufacturers to isolate issues within minutes rather than days." Murali Manohar Regional Leader - Enterprise Software Business - India & SE Asia, Rockwell Automation
What advantages does Plex offer automotive suppliers compared to generic MES platforms? Can you quantify timeto- value and ROI?
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"Plex provides real-time genealogy tracking, allowing manufacturers to isolate issues within minutes rather than days." Murali Manohar Regional Leader - Enterprise Software Business - India & SE Asia, Rockwell Automation
What advantages does Plex offer automotive suppliers compared to generic MES platforms? Can you quantify timeto- value and ROI?
Plex was purpose-built for the automotive industry, meaning it comes pre-configured with the specific workflows, compliance standards, and reporting requirements that Tier-1 and Tier-2 suppliers face every day. Unlike generic MES platforms, which often require extensive customization to meet automotive standards, Plex includes built-in support for critical processes like Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP), Failure Mode and Effects Analysis (FMEA), and IATF 16949 compliance.
This dramatically reduces deployment time and complexity. For example, automotive suppliers have been able to implement Plex and go live in as little as 60 days, compared to the 6–12 months typically required for generic MES solutions. This rapid deployment is possible because Plex’s workflows and compliance features are ready out of the box, minimizing the need for costly and time-consuming customizations.
Once operational, suppliers have reported significant improvements in key performance metrics. Production efficiency has increased by up to 75% within the first few months, inventory turns have improved by 5–10%, and scrap rates have decreased, all contributing to a faster return on investment—often within 6–9 months.
How does Plex digitize APQP and PPAP, and what impact does this have on submissions and audits?
APQP and PPAP are foundational quality processes in automotive manufacturing, but they have traditionally been paperintensive and laborious. Plex transforms these processes by digitizing every step and integrating them directly into live production workflows. All eighteen elements of PPAP, including control plans, FMEAs, and process flow diagrams, are linked to actual shop-floor activities, ensuring real-time compliance and eliminating manual data entry.
Operators and machines automatically capture quality checks and inspection results, which are instantly populated into the relevant APQP and PPAP documentation. Built-in templates for ISO and IATF standards, deviation tracking, and corrective actions ensure that all documentation is audit-ready at any time. This digital transformation has led to dramatic reductions in PPAP submission times.
Suppliers report that compiling PPAP packages, which used to take weeks of manual effort, can now be completed in days—often cutting submission time by 50–70%. Audits are also much more efficient, as all records are centralized, up-to-date, and accessible with a single click. Instead of spending days preparing for customer audits, teams can demonstrate compliance instantly, with full traceability and historical records available in real time.
How does end-to-end traceability help contain recalls? Can you share a real-world example?
End-to-end traceability is essential in automotive manufacturing, especially given the complexity of modern supply chains and the increasing number of components in electrified vehicles. Plex enforces serialization and container-level tracking at every stage of production, from raw material receipt to final assembly and shipping. Every transaction—who handled the material, where it moved, and what operations were performed—is recorded, creating a comprehensive traceability tree.
A real-world example illustrates the value of this capability: When a batch of raw material was flagged for potential contamination, a supplier using Plex was able to instantly identify all downstream components and assemblies that used material from the affected batch.
Instead of recalling thousands of finished units, the supplier quarantined only twelve specific assemblies, saving millions in recall costs and maintaining strong relationships with OEM customers. This rapid containment is possible because Plex provides real-time genealogy tracking, allowing manufacturers to isolate issues within minutes rather than days. Complete digital records also ensure instant response to OEM or regulatory inquiries, supporting compliance and audit readiness.
How does Plex act as the digital backbone for smart factories, including IoT and predictive maintenance? What measurable outcomes have been seen?
Plex serves as the central nervous system for smart factory transformations by collecting, contextualizing, and analyzing data from machines, sensors, and IoT devices across the shop floor. It connects directly to production equipment using various protocols, ensuring that data is not just collected but also linked to specific manufacturing processes.
For example, a temperature reading from a sensor is tied to a particular part number, machine, and time, providing meaningful context for quality control and process optimization. This data is fed into predictive maintenance systems, which can automatically generate work orders when anomalies are detected, shifting maintenance from reactive to proactive.
Manufacturers benefit from real-time visibility into machine states, cycle times, and quality outputs, enabling comprehensive tracking of Overall Equipment Effectiveness (OEE). By leveraging automated, accurate data instead of manual entries, manufacturers can quickly identify bottlenecks and inefficiencies, driving significant improvements in OEE and substantial reductions in unplanned downtime.