How Axion Automotive Parts Increased On-Time Delivery to 98% Across 5 Plants with ArionERP

Discover how a Tier-1 automotive supplier transformed its chaotic, multi-site production scheduling into a synchronized, efficient, and predictable manufacturing powerhouse.

22%

Increase in Overall Equipment Effectiveness (OEE)

30%

Reduction in Production Lead Times

98%

On-Time Delivery Rate Achieved

Client Overview

Axion Automotive Parts is a Tier-1 supplier of precision-engineered components for major automotive OEMs. With over $500 million in annual revenue, they operate five specialized manufacturing facilities across the United States, each focusing on different product lines, from transmission gears to electronic sensor housings. Their reputation is built on quality and reliability, but their internal processes were struggling to keep pace with the demands of just-in-time (JIT) manufacturing and increasingly complex global supply chains.

The Challenge: Five Plants, One Giant Headache

Before ArionERP, Axion's multi-plant operations were a masterclass in organized chaos. Each facility used its own disparate system for production scheduling—a mix of legacy MRP software, custom-built databases, and a dizzying array of "master" spreadsheets. This siloed approach created a cascade of critical business challenges.

Zero Visibility: Management had no unified view of production capacity. Shifting a large order from an overloaded plant to one with spare capacity was a manual, week-long process of phone calls and data reconciliation.
Constant Bottlenecks: A delay at one plant would have an unknown ripple effect on the others, leading to frequent, costly production stoppages and missed deadlines. Their on-time delivery rate hovered around a dismal 75%.
Inefficient Resource Allocation: High-value machinery and skilled labor were often idle at one facility while another was struggling with a backlog, leading to excessive overtime costs and underutilization of assets.
Inaccurate Forecasting: Without a central data source, sales teams couldn't provide reliable delivery dates to clients, eroding trust and putting major contracts at risk.

The Solution: A Unified Nervous System with ArionERP

Axion needed more than just software; they needed a central nervous system for their entire manufacturing operation. They chose ArionERP for its powerful, AI-enhanced Advanced Planning and Scheduling (APS) module and its proven ability to unify complex, multi-site environments. The implementation was a strategic partnership focused on creating a single source of truth.

Centralized Master Production Schedule (MPS): We integrated all five plants into a single ArionERP instance. Now, production planners have a real-time, global view of all work orders, capacity, and material availability.
AI-Powered Scheduling Engine: ArionERP's APS module automatically analyzes constraints (machine availability, labor skills, material lead times) across all sites to generate optimized production schedules. The system can run "what-if" scenarios in minutes, not days.
Dynamic Load Balancing: When a new high-priority order arrives, the system automatically identifies the optimal plant to produce it, considering current loads, material on hand, and shipping logistics to the end customer.
Real-Time Shop Floor Integration: By connecting ArionERP directly to their shop floor equipment, Axion gained real-time progress updates. Planners can see the exact status of any job, at any plant, from a single dashboard, allowing for proactive problem-solving.

Tangible Outcomes

The Results: From Chaos to Competitive Advantage

By replacing five disconnected systems with one intelligent platform, Axion didn't just solve their scheduling problems—they fundamentally transformed their operational capability. The ROI was immediate and substantial.

22%

Increase in OEE

Optimized scheduling and reduced downtime led to a massive boost in asset utilization across all facilities.

98%

On-Time Delivery

Predictable production and accurate forecasting restored customer confidence and secured key contracts.

30%

Shorter Lead Times

Streamlined workflows and proactive bottleneck management cut the average time from order to shipment significantly.

40%

Reduction in Expedite Costs

With better planning and visibility, the need for expensive rush shipping and last-minute material orders plummeted.

ArionERP gave us the one thing we never had: a single version of the truth. We went from guessing to knowing. Our planners can now make strategic decisions that benefit the entire enterprise, not just their individual plant. The impact on our efficiency and customer satisfaction has been nothing short of revolutionary.

Vincent Sellers

VP of Operations, Axion Automotive Parts

Technology Deep Dive

Key ArionERP Modules Deployed

Advanced Planning & Scheduling (APS)

The core engine of the transformation. Our APS module provided finite capacity scheduling, constraint modeling, and AI-driven optimization to create the most efficient production plan possible across all five sites.

Real-time visibility into machine and labor capacity.
"What-if" scenario planning for demand fluctuations.
Automated bottleneck detection and resolution alerts.

Material Requirements Planning (MRP)

Synchronized material planning with production schedules, ensuring that raw materials and components were available at the right plant, at the right time, eliminating costly delays.

Automated purchase order generation based on demand.
Multi-plant inventory visibility and transfer recommendations.
Integration with supplier lead times for accurate planning.

Manufacturing Execution System (MES)

Bridged the gap between the plan and the reality on the shop floor. The MES module provided real-time data capture, work order tracking, and performance monitoring.

Paperless work instructions and data collection.
Live OEE and scrap rate tracking.
Direct integration with PLCs and machine sensors.

Quality Management

Embedded quality checks and compliance requirements directly into the production process, ensuring consistent standards across all facilities and providing full traceability for automotive audits.

In-process quality data collection and statistical process control (SPC).
Non-conformance and corrective action (CAPA) workflows.
Automated generation of certificates of analysis.

Got Questions?

Your Multi-Plant Scheduling Questions, Answered

ArionERP allows you to define unique factory calendars for each plant, including different shift patterns, holidays, and planned maintenance schedules. The Advanced Scheduling engine considers each plant's specific availability when creating the master production schedule, ensuring plans are realistic and achievable for every location.

Yes. This is a core strength of our multi-plant solution. When a new sales order is entered, the system can be configured to automatically evaluate multiple factors—such as current capacity load, material availability, specific machine capabilities, and even shipping costs to the customer's location—to recommend the most optimal plant for production.

When an unplanned downtime event is logged, ArionERP immediately flags all affected work orders. Planners receive an alert and can use the "what-if" scenario tool to instantly see the impact. They can then drag-and-drop the affected jobs to an alternative work center, either in the same plant or another facility, and the system will automatically re-calculate the entire schedule in minutes.

ArionERP provides complete visibility of inventory across all locations. The system manages inter-plant transfers as a standard transaction, allowing you to move stock from one facility to another to meet production needs. The MRP engine accounts for in-transit inventory, ensuring that planners have an accurate picture of what's available and when it will arrive.

Implementation timelines vary based on complexity, but our structured methodology is designed for efficiency. A multi-plant rollout typically follows a phased approach, starting with a pilot plant to establish a template, followed by accelerated rollouts to subsequent sites. A typical 3-5 plant implementation can range from 6 to 12 months. Our "Pro" and "Enterprise Plus" implementation packages are designed to guide you through every step of this process.

Ready to Synchronize Your Manufacturing Operations?

Stop juggling spreadsheets and start orchestrating your production with intelligence. See how ArionERP can provide the visibility and control you need to turn your multi-plant challenges into a powerful competitive advantage.

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