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Headquartered in Lancaster, New York, Moldtech, Inc. is a leading North American developer and manufacturer of custom rubber molded products. With a complete line of custom manufacturing equipment, the Moldtech team serves a wide variety of industries, including Automotive, Aerospace, Electronics, and Industrial.
- Delayed and inaccurate reporting due to poor plant floor visibility
- Limited digitization hindered access to trustworthy data
- Lacked control over materials and finished goods and had near-zero inventory accuracy
- Decreased cost of scrap by nearly 50%
- Improved efficiency by 10-20%
- Found approximately $25,000 in savings in first quarter of 2025
- Achieved strong culture of quality
Challenge
Moving Beyond Disparate Systems
As a North American manufacturer of rubber molded products, Moldtech Inc. has evolved significantly over the past 25 years. With a goal to continue progressing and a shared priority of scalability and quality, the Moldtech team knew they had to fill the gaps between their desired goals and the limits of their legacy system. Specifically, their existing infrastructure relied on basic functionality, forcing the team to supplement reporting and tracking with spreadsheets and additional software.
“We wanted a solution that gave us real time inventory levels, live production metrics, and accurate costing,” says Edward Halady, President, Moldtech Inc. Limited digitization, plant floor visibility, and oversight of materials led to delayed reporting and unreliable data. Moldtech knew they needed to search for a new, single platform that could connect their business and plant floor operations.
Solution
Progress to a Unified Plex Platform
Moldtech began their search for a holistic MES system by conducting a structured evaluation of available solutions. The team researched several options, narrowing the field through research, speaking with real users, in-depth demonstrations, and an internal ranking survey and selection matrix. After deeper analysis and commercial discussions, the team selected the Plex Smart Manufacturing Platform to serve as their unified system across operations.
Moldtech followed a team approach to their Plex implementation. Team members took the lead based on areas of Plex that aligned to their job roles. A unique and collaborative process proved to be critical, as the company also restructured their organization and rebuilt the team amidst the implementation. What could have slowed progress was described by Halady as fairly seamless. Moldtech brought on new employees and trained them within Plex directly, blending the onboarding process naturally with the implementation phase.
Result
Reduced Scrap and Increased Opportunities for Visibility
Moldtech completed the Plex implementation in six months and began seeing benefits almost immediately after going live. Efficiency gains, decreased scrap, and cost savings allowed the company to continue pursuing their goal of producing quality, cost-effective products.
Weekly reviews that once required manual compilation of scrap data and new chart creation became automated with detailed data pulled directly from Plex. Now, all members have access to scrap trends, dollar values, percentage of sales, and more. Everyone on the shop floor is motivated by real data, time savings, and increased efficiency. Moldtech is working to fully implement Plex MES A&O, and their data will undoubtedly only continue to improve.
Since Moldtech’s transition to Plex, scrap costs dropped by nearly half, and the company saved $25,000 during the first quarter of 2025 versus the anticipated budget. The team attributes these savings to the efficiency and insights delivered by Plex technology. “We have live scrap reporting available to us now, allowing us to know exactly what impact our scrap will have on month end bottom-line,” shares Halady.
Building Confidence and Efficiency Across the Organization
The Moldtech team also saw their efficiency increase by 10–20%, impacting labor planning, throughput, and quality management. With Plex in place as the backbone of production, the team operates with greater confidence that they will continue to find new ways to use the solution’s capabilities. Prior to implementing Plex, Moldtech encountered many hurdles when meeting production expectations. Plex removes the guesswork, allowing the team to focus on how to use the solution to meet their goals.
New Financial Accuracy and Planning
Moldtech also saw significant gains with the robust accounting capabilities that Plex offers. Financial transactions are now easily accessible, and the team can anticipate month end figures in advance. During the first quarter of 2025, the company reported $4 million in sales, with projected financials within $2,500 of the actual results. This remarkable accuracy demonstrates their improved visibility into costs and margins.
“We’ve never had such accurate reporting. We can truly rely on our cost data to make informed business decisions. It’s been a huge win for us.”
Edward Halady - President, Moldtech Inc.
Positioned for Future Growth
Before implementing Plex, Moldtech also lacked systemization and scalability. They operated across disparate systems with limited trust in data. Today, the organization is equipped with a unified platform that supports growth, consistency, and continuous improvement. “We wouldn’t be where we are today without Plex,” Halady concludes.
Disclosure
This case study is a replicated version, with the original available on the Plex website. To access the original version, please click here: https://plex.rockwellautomation.com/en-us/case-studies/moldtech-saves-with-plex.html
Published March 20, 2026