AI-Powered ERP for the Plastics & Rubber Industry
Finally, an ERP that understands family molds, regrind management, and lot traceability.
Stop fighting generic software. Start shipping perfect parts, on time, every time.
Trusted by Leading Manufacturers and Global Brands
Why Plastics & Rubber Manufacturers Choose Us
Built for Your Industry
Our ERP isn't a generic solution with manufacturing bolt-ons. It's engineered from the ground up to handle the specific complexities of plastics and rubber processing, from BOMs with regrind percentages to family mold management.
AI-Driven Scheduling
Move beyond static spreadsheets. Our AI engine analyzes machine capacity, tool availability, material lead times, and labor to create dynamic, optimized production schedules that reduce downtime and improve on-time delivery.
Granular Traceability
Achieve complete, forward-and-backward lot traceability from raw material receipt to finished product shipment. Meet the strictest standards of automotive (IATF 16949), medical (FDA), and other regulated industries with confidence.
Scrap & Waste Reduction
Identify the root causes of scrap with real-time shop floor data collection. Our analytics help you pinpoint issues with machines, molds, or materials, allowing you to make data-driven improvements that directly impact your bottom line.
Real-Time Job Costing
Know the true cost of every part you produce. We capture actual material, labor, machine, and overhead costs in real-time, giving you precise margin analysis and enabling more competitive and profitable quoting.
Rapid, Phased Implementation
We get you live and seeing ROI faster. Our proven `QuickStart` methodology focuses on core processes first, minimizing business disruption and ensuring your team adopts the system successfully before moving to advanced modules.
Expert U.S.-Based Support
Our support team isn't just technically proficient; they are manufacturing process experts. When you have a question, you're talking to someone who understands your industry and can provide practical, effective solutions.
A Scalable Growth Platform
ArionERP grows with you. Whether you're adding a new production line, acquiring another facility, or expanding into new markets, our flexible architecture provides the foundation for sustainable, long-term growth.
Compliance Built-In
Simplify audits and quality management. Our system has built-in workflows and documentation capabilities to support ISO 9001, IATF 16949, and other critical quality standards, making compliance a seamless part of your operation.
One Integrated ERP for Your Entire Operation
Production Planning & Scheduling
Create, manage, and optimize your production schedule with unparalleled visibility and control.
- AI-Powered Scheduling: Automatically generate optimal schedules based on real-time constraints.
- Drag-and-Drop Gantt Chart: Easily visualize and adjust your production plan on the fly.
- Capacity Planning: Analyze work center and machine load to prevent bottlenecks.
Bill of Materials (BOM) & Routing
Define and manage complex product structures and manufacturing processes with precision.
- Multi-Level BOMs: Handle intricate assemblies and sub-assemblies with ease.
- Regrind & Recycle Integration: Accurately factor recycled materials into your BOMs and costing.
- Version Control: Maintain a full revision history of BOMs and routings for engineering changes.
Manufacturing Execution System (MES)
Connect your top floor to the shop floor with real-time data collection and machine monitoring.
- Real-Time Data Capture: Track production counts, cycle times, and downtime automatically.
- Operator Interface: Provide simple, intuitive terminals for manual data entry and work instructions.
- Overall Equipment Effectiveness (OEE): Monitor and improve the performance of your key assets.
Tool, Die & Mold Management
Maximize the life and performance of your most critical assets with a dedicated tool management module.
- Usage & Cycle Tracking: Monitor tool usage and schedule preventative maintenance automatically.
- Family Mold Management: Efficiently schedule and track production for multi-cavity and family molds.
- Location & Status Tracking: Always know the location, condition, and availability of every tool.
Quality Management (QMS)
Embed quality into every step of your process, from receiving to final inspection.
- In-Process Inspections: Define and enforce quality checks at critical routing steps.
- Non-Conformance Reporting (NCR): Systematically document, track, and resolve quality issues.
- Corrective and Preventive Actions (CAPA): Manage the entire CAPA lifecycle to drive continuous improvement.
Lot & Serial Traceability
Gain end-to-end visibility into your product lifecycle for ultimate control and compliance.
- Bin-to-Bin Tracking: Track materials from the moment they enter your warehouse.
- Full Genealogy: Instantly generate reports tracing finished goods back to raw material lots.
- Mock Recalls: Perform mock recalls in minutes, not days, to satisfy auditor requirements.
Document Control & Compliance
Centralize and manage all critical documents, ensuring your team always has the latest version.
- Revision Control: Link work instructions, prints, and SOPs directly to routings and parts.
- Audit Trails: Maintain a complete history of all changes for full accountability.
- Compliance Reporting: Generate Certificates of Conformance (CoC) and other compliance documents automatically.
Inventory Management
Optimize inventory levels to reduce carrying costs while ensuring material availability.
- Regrind Inventory Control: Specifically track and value recycled materials separately.
- Cycle Counting: Improve inventory accuracy with systematic counting programs.
- Min/Max & Reorder Points: Automate procurement suggestions based on usage and lead times.
Supply Chain Management (SCM)
Streamline procurement, manage suppliers, and gain visibility across your entire supply chain.
- Purchase Order Management: Automate the procure-to-pay process.
- Supplier Performance: Track on-time delivery and quality ratings for your vendors.
- AI-Powered Demand Forecasting: Predict future material needs based on historical data and sales forecasts.
Warehouse Management (WMS)
Improve warehouse efficiency and accuracy with advanced WMS capabilities.
- Barcode & RF Scanning: Enable mobile transactions for receiving, picking, and shipping.
- Directed Put-Away & Picking: Optimize warehouse workflows with system-guided tasks.
- Label Printing: Generate custom labels, including AIAG standards for automotive suppliers.
Financials & Accounting
Integrate your financial operations with your manufacturing data for a single source of truth.
- Real-Time Cost Roll-Ups: Understand the impact of material and labor cost changes instantly.
- General Ledger, AP, AR: A complete, integrated accounting suite.
- Financial Reporting: Generate P&L statements, balance sheets, and cash flow reports with ease.
Sales & CRM
Manage the entire customer lifecycle from lead to quote to order to cash.
- Accurate Quoting: Generate complex quotes quickly based on material, labor, and machine costs.
- Order Management: Convert quotes to sales orders and production jobs with a single click.
- Customer Portal: Provide customers with self-service access to order status and history.
Reporting & Business Intelligence
Turn your data into actionable insights with powerful, easy-to-use reporting tools.
- Role-Based Dashboards: Give every user the key metrics they need to perform their job effectively.
- Custom Report Writer: Build your own reports without needing a developer.
- KPI Tracking: Monitor key performance indicators like OEE, scrap rate, and on-time delivery.
AI-Powered Predictive Maintenance
Proactively maintain your equipment to prevent costly unplanned downtime.
- Anomaly Detection: AI models monitor machine data to predict potential failures.
- Automated Work Orders: Automatically generate maintenance work orders based on predictions or usage.
- Spares Management: Ensure you have the right spare parts on hand for planned maintenance.
Human Resources (HR)
Manage your most valuable asset—your people—more effectively.
- Time & Attendance: Track employee hours and integrate directly with job costing and payroll.
- Skills Matrix: Manage employee certifications and training records.
- Payroll Integration: Seamlessly connect to popular payroll services.
Our Customer Success Stories
Automotive Supplier Achieves IATF Compliance and Drastically Reduces Scrap
A mid-sized injection molder serving the automotive industry was struggling with manual, paper-based processes. They faced high scrap rates, inconsistent on-time delivery, and dreaded their IATF 16949 audits, which required weeks of preparation.
Key Challenges:
- Lack of real-time visibility into production and scrap.
- Inability to perform fast and accurate lot traceability for audits.
- Inefficient scheduling leading to machine downtime and late orders.
- Inaccurate job costing that eroded profit margins on key product lines.
Our Solution:
We implemented ArionERP with a focus on shop floor data collection and quality management. The phased rollout started with MES and QMS modules to deliver the most immediate impact.
- Deployed real-time production monitoring on all injection molding machines.
- Implemented barcode scanning for raw material receiving and WIP movement.
- Configured the QMS module to enforce IATF-compliant inspection plans.
- Utilized the AI scheduling engine to optimize press utilization and minimize changeover times.
Medical Packaging Firm Achieves Flawless FDA Traceability and Boosts Capacity
A manufacturer of thermoformed packaging for sterile medical devices needed to upgrade its legacy system to meet stringent FDA regulations and improve production efficiency. Their existing system couldn't provide the granular device history records (DHR) required by auditors.
Key Challenges:
- Inadequate lot traceability to meet 21 CFR Part 820 requirements.
- Manual and error-prone paper-based production records.
- Difficulty managing cleanroom production protocols and documentation.
- Poor inventory control leading to stockouts of critical raw materials.
Our Solution:
We implemented ArionERP's full suite, with a special focus on the QMS, Lot Traceability, and Document Control modules, configured for medical device manufacturing.
- Established a fully electronic Device History Record (eDHR) system.
- Integrated barcode scanning at every step, from material consumption to cleanroom packaging.
- Attached all SOPs and work instructions digitally to production routings.
- Automated the generation of Certificates of Conformance for every shipment.
Custom Rubber Extruder Increases Profitability with Accurate Quoting and Costing
A custom rubber extrusion company that produces seals, gaskets, and profiles for various industries was struggling with profitability. Their complex quoting process, based on tribal knowledge and spreadsheets, often resulted in under-quoted jobs and surprise losses.
Key Challenges:
- Inability to accurately estimate material and labor costs for custom jobs.
- Long lead times for generating quotes, causing them to lose bids.
- Poor tracking of diverse rubber compounds and their associated costs.
- No visibility into actual vs. estimated costs after a job was completed.
Our Solution:
We implemented ArionERP's Sales & Quoting module along with the core manufacturing and financial packages to create a seamless quote-to-cash process.
- Built a quoting engine that accurately calculates costs based on material, die complexity, machine rates, and labor.
- Created a centralized database for all rubber compound recipes and their current costs.
- Implemented real-time job costing to compare actual production costs against the original quote.
- Used historical job data to refine quoting parameters and improve future estimates.
Technology Stack & Tools
ArionERP is built on a modern, flexible technology stack, ensuring seamless integration with your existing systems and future-proofing your investment.
Real Stories, Real Impact
"The level of detail in the lot traceability is phenomenal. We can pull a full genealogy report in seconds, which has been a game-changer for our ISO audits. The system paid for itself in the first year just from the time saved on compliance paperwork."
"We cut our unplanned machine downtime by over 30% in six months thanks to the predictive maintenance module. The AI alerts us to potential issues before they become catastrophic failures. It's like having a crystal ball for our equipment."
"As a CFO, I live in the data. ArionERP gives me a real-time, accurate view of our profitability by part, by customer, and by machine. We've identified and fixed unprofitable jobs we'd been running for years. The financial visibility is unparalleled."
"The shop floor interface is so intuitive. Our operators picked it up in a day. Getting real-time production data has eliminated the 'black hole' between shifts and helped us improve our OEE by 15 points."
"The implementation team were true partners. They took the time to understand our unique extrusion process and configured the system to match our workflow. This wasn't a one-size-fits-all deployment; it was a tailored solution."
"Our inventory accuracy went from 85% to 99.5%. The WMS module with barcode scanning eliminated shipping errors and gave us the confidence to implement a just-in-time material strategy, which freed up a significant amount of working capital."
Frequently Asked Questions
ArionERP has a dedicated functionality for managing regrind. You can define regrind as a separate inventory item, track its generation from scrap, and specify its allowable percentage in your Bills of Material (BOMs). The system will automatically factor its (often lower) cost into your job costing, giving you a true picture of profitability while maximizing material usage.
Yes. Our Manufacturing Execution System (MES) module is designed to integrate with a wide range of industrial equipment through standard protocols like OPC-UA and MQTT, or via hardware data acquisition devices. This allows for the automatic collection of cycle counts, machine status, downtime reasons, and other critical production data, eliminating manual entry and providing real-time OEE metrics.
We offer both options to fit your business needs and IT strategy. Our secure, multi-tenant cloud (SaaS) offering, hosted on AWS or Azure, eliminates the need for you to manage servers and infrastructure. For companies with specific security requirements or existing data centers, we also offer a full-featured on-premise deployment.
Implementation time varies based on complexity, but our goal is to get you live on core functionality as quickly as possible. Our `QuickStart` package for smaller businesses can be live in as little as 8-12 weeks. A more complex, multi-module implementation for a mid-sized manufacturer typically takes 4-6 months. We use a phased approach to ensure you start seeing value early in the process.
Our Tool & Die Management module is built for this. You can define a tool as a "family mold" and link multiple part numbers to it. When you schedule a job for one part, the system understands that all parts in the family are being produced simultaneously. It correctly allocates machine time and material consumption across all parts, ensuring accurate inventory counts and costing for each individual part number produced in the shot.
We believe successful adoption is key to ROI. Your implementation includes comprehensive training for your team, tailored to their specific roles. Post-launch, we offer tiered support packages, from standard business-hour helpdesk to 24/7 premium support. All our support staff are U.S.-based and have deep expertise in manufacturing processes, ensuring you get knowledgeable help when you need it.
Ready to Transform Your Plastics & Rubber Operations?
Stop letting generic software dictate your workflow. Schedule a free, no-obligation consultation with one of our industry experts. We'll discuss your specific challenges and demonstrate how ArionERP can provide the control, visibility, and efficiency you need to grow your business.
Schedule Your Free Demo Today