How Plasman Cut Changeover & Maintenance Downtime with Real-Time, Operator-Driven Insights
Client
Industry:
Automotive Manufacturing
Built-In Value:
Real-Time Visibility
Machines
Connected:
Reading time:
~3 minutes
Plasman is a global automotive supplier specializing in injection-molded exterior components for major automotive brands. Operating in a high-mix, high-precision environment, Plasman’s Windsor plant knew that changeovers and maintenance downtime were unavoidable, but unmanaged downtime was not.
After struggling with limited visibility and adoption from a legacy system, Plasman turned to Shoplogix to bring clarity, accountability, and real-time insight to the shop floor.
They’ve been using Shoplogix since November 2023, and the impact has been immediate.
On top of that:
The result? Too much time reacting, not enough time improving.
Changeover time fluctuated wildly between jobs
Maintenance events were logged, but not consistently analyzed
Setup time was often mis-coded or blended into other downtime categories
Supervisors relied on experience instead of data to assign jobs and operators
Everyone knew there were opportunities, they just couldn’t see them clearly.
After evaluating 30 different solutions, Mondelez selected Shoplogix Smart Factory Suite to complete its IDF strategy.
Why Shoplogix?
Because it connects directly to machines, delivers real-time operational visibility, and empowers operators, supervisors, and leadership with the same trusted data — instantly.
Plasman deployed Shoplogix Core + Labor Module, enabling:
What’s Next: SMED Insights
Plasman is now rolling out Shoplogix SMED insights, measuring true part-to-part time to:
Changeovers
Total changeover hours cut by more than 60% from peak levels
Time per changeover reduced from ~2 hours to under 1 hour
Sustained improvement month after month, not a one-time gain
Maintenance Downtime
Clear, consistent downward trend in maintenance DT
Faster response to issues that actually impact production
Less guesswork, more targeted action
Labour Efficiency
Data-driven scheduling replacing assumptions
Visibility into operator strengths by part and machine
Improved collaboration between supervisors, operators, and maintenance
“Overall, as a team we love the product, love the collaborative approach that Shoplogix and Plasman have established, and love the gains through ‘LIVE’ data and visualization that the platform provides.”
Changeovers are not “fixed”, they’re measurable and improvable
Live, trusted data drives faster adoption than reports ever could
Labour efficiency improves when performance is visible, not personal
Sustainable gains come from engaging the floor, not just the office
This case proves that:
Shoplogix bridges the gap between the shop floor and leadership, turning everyday production data into measurable performance gains.
Hop on a free no-commitment strategy call with one of our manufacturing experts to learn more.
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