Thai Summit America Plex MES Case Study: Downtime and Throughput Gains

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Thai Summit America Plex MES Case Study: Downtime and Throughput Gains

Case study showing how Thai Summit America used Plex MES Automation & Orchestration to cut downtime 80 percent and raise throughput 70-112 percent.

Published

June 4, 2026

Read time

3 min read

Source

Thai Summit America, an automotive sheet metal stamper in Howell, Michigan, replaced paper and spreadsheet processes with Plex MES A&O in 2017. The system automatically captures machine status, records downtime reasons, and surfaces micro-stoppages. Results include an 80 percent reduction in shift downtime, mean time between failures rising from 10-20 to 40 minutes, and revenue per line increasing from $8,000 to $12,000 per hour.

Key takeaways

80 percent reduction in daily downtime after MES A&O rollout

Throughput increased 70-112 percent, from 40-50 to 85 jobs per hour

Mean time between failures extended from 10-20 minutes to 40 minutes

Automated downtime logging replaced manual plant-floor checks

Employee suggestions delivered at least $3 million annual cost savings

Market overview

SCR methodology note

Vendor landscape

Leaders

Implementation considerations

Important consideration

Original Source

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