Gerdau, a global leader in steel production, has achieved significant cost savings and operational improvements by implementing Plex Process Flows, a low-code automation solution from Rockwell Automation's Plex Smart Manufacturing Platform. This development comes as manufacturers increasingly seek efficient solutions to streamline operations and reduce costs.
What Happened
Gerdau's North American special steel division faced challenges in maintaining real-time visibility and consolidating key performance indicators due to legacy systems. To address these issues, they adopted the Plex Smart Manufacturing Platform, which modernized operations and unified processes. A pivotal enhancement was the use of Plex Process Flows, allowing Gerdau to build automated workflows without extensive software development.
The automation processes developed with Plex Process Flows have streamlined Gerdau's quality control operations, notably by automatically managing overweight container shipments, thus reducing customer complaints and rework costs. Additionally, automations have significantly reduced manual tasks, such as updating container statuses, enhancing efficiency and saving an estimated $30,000 in development costs by replicating work-request features in-house.
What This Means for Your Business
The integration of low-code automation tools like Plex Process Flows can provide substantial benefits for manufacturers. By reducing reliance on external development resources, companies can cut costs and improve operational efficiencies. This case demonstrates a practical application of automation in quality control and inventory management, which can be particularly beneficial for firms looking to optimize processes without extensive IT investments.
For AECM professionals, leveraging similar low-code solutions offers opportunities to enhance compliance with industry standards such as CMMC and NIST, while ensuring robust quality control mechanisms are in place. The cost savings and efficiency gains also present a competitive advantage, allowing firms to reallocate resources to strategic growth initiatives.
What US Operators Should Watch
Operators should monitor advancements in low-code and no-code automation platforms, as they offer a pathway to modernize legacy systems and improve operational resilience. Additionally, staying informed about federal funding opportunities that support digital transformation in manufacturing can provide financial incentives for adopting such technologies. As more firms embrace automation, the ability to quickly adapt and integrate these solutions will be crucial in maintaining a competitive edge.
Source: http://www.ManufacturingTomorrow.com/news/2026/06/10/gerdau-saves-30000-in-development-costs-and-reduces-manual-work-with-plex-process-flows/27736. Read the original story ->
Partner Insight · VisioneerIT
The integration of low-code automation tools like Plex Process Flows aligns with VisioneerIT's focus on digital modernization and workflow automation. By leveraging such technologies, manufacturers can enhance operational efficiencies and modernize legacy systems effectively.
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