Revolutionizing Manufacturing with Plex Mobile: Your Gateway to Smart, Connected Operations
Manufacturing operations today demand real-time agility, precision, and seamless connectivity between systems, people, and processes. Plex Mobile, developed by Rockwell Automation, addresses these critical needs by putting enterprise-level control and information sharing directly into the hands of shop floor employees through intuitive mobile technology.
The Business Case for Mobile Manufacturing
The manufacturing landscape has fundamentally shifted from paper-based processes to digitally connected operations. Traditional methods of documenting inventory, production data, and quality metrics on paper, collecting it manually, and then collating it have become not just inefficient but competitively disadvantageous. Manufacturers operating without mobile solutions face several critical challenges:
Operational inefficiencies result from disconnected systems requiring manual data entry, increasing error rates and consuming valuable time that could be spent on value-added activities. Quality control gaps emerge when workers rely on paper-based quality data collection, creating information silos that deplete resources and compromise decision-making. Inventory inaccuracies plague manufacturers who lack real-time visibility into stock levels, leading to shortages, overstock situations, and missed customer deliveries.Core Capabilities and Strategic Benefits
Plex Mobile transforms manufacturing operations through several key capabilities that directly address industry challenges:
Real-Time Data Integration and Visibility
Plex Mobile enables instant data capture and sharing across all manufacturing processes. Workers can scan barcodes, update inventory, track production progress, and manage quality checks in real-time, with all information immediately available to enterprise systems. This eliminates the traditional delays associated with batch data processing and provides management with accurate, up-to-date operational insights.Companies implementing Plex Mobile report eliminating monthly material cost discrepancies by over 92% while reducing inventory tracking processes from six days per month to just a few hours. This real-time visibility enables manufacturers to make data-driven decisions quickly and respond to changing conditions without delay.
Role-Based Workflow Optimization
The application features role-based menus and functionality specifically designed to support individual operators and their specific responsibilities. Rather than presenting users with overwhelming universal interfaces, Plex Mobile tailors each experience to match the user's role, from materials handlers to quality inspectors to shipping coordinators.
This targeted approach improves workforce efficiency and accuracy while reducing training time and minimizing the potential for user errors. Workers can complete entire workflows from start to finish without switching between multiple applications or systems.Native Mobile Device Utilization
Plex Mobile leverages native mobile device capabilities including camera functionality, audio confirmation, vibration feedback, and Bluetooth connectivity to streamline operations. For example, workers can use device cameras for barcode scanning, receive audio confirmations for successful operations, and connect external scanning equipment via Bluetooth.
The application supports both 1D and 2D barcode formats, with 1D barcodes conveying single pieces of information (like quantity) prefixed with designator characters, while 2D barcodes can combine multiple data points into a single scannable code. This flexibility accommodates various labeling and tracking requirements across different manufacturing environments.Supported Modules (As of 10-2025)
Solving Critical Manufacturing Challenges
Supply Chain and Inventory ManagementPlex Mobile addresses the supply chain challenges that 79% of manufacturers report lacking complete solutions for. The mobile application enables real-time inventory tracking, automated receiving processes, and immediate visibility into stock levels across all locations.
Manufacturers using Plex Mobile report significant improvements in inventory accuracy and reduction in carrying costs. One automotive supplier eliminated $250,000 annually in inventory waste while reducing chargebacks from late production. The system's automated serialized inventory tracking provides real-time visibility into the physical movement and location of goods, enabling better demand forecasting and supply chain optimization.
Quality Control and Compliance
Quality remains the number one outcome manufacturers hope to achieve from smart manufacturing technology. Plex Mobile enables electronic quality checks throughout production processes, replacing error-prone manual documentation with automated, standardized procedures.
The application supports comprehensive traceability requirements, particularly critical for industries like aerospace and automotive manufacturing. Companies report achieving over 95% improvement in label accuracy and significant reductions in quality-related incidents. Electronic quality data collection eliminates information silos and ensures consistent compliance with regulatory standards.
Workforce Productivity and Engagement
With 94% of manufacturers expecting to maintain or grow their workforce as smart manufacturing technology adoption increases, Plex Mobile addresses the critical need for tools that enhance rather than replace human workers. The application provides workers with real-time guidance, reduces manual tasks, and eliminates redundant data entry.
Studies show that embedded collaboration features in Plex Connected Worker increase productivity by 25%. Workers can communicate seamlessly across the shop floor and company through integrated Microsoft Teams functionality, improving coordination and problem-solving capabilities.
Technology Strategy and Implementation
Cloud-Native Architecture
Plex Mobile operates as an extension of the cloud-based Plex Smart Manufacturing Platform, eliminating the need for local server infrastructure or complex version management. This SaaS approach ensures all users access the most current version of the software while providing automatic updates and enhanced security.
The cloud architecture enables manufacturers to scale operations without significant IT infrastructure investments. Companies report 15% reductions in energy consumption and monthly IT maintenance costs while redeploying 50% of IT staff to more strategic activities.Integration and Connectivity
Plex Mobile seamlessly integrates with existing manufacturing systems while providing connectivity to modern IoT devices, sensors, and automation equipment. This integration capability supports the Industrial Internet of Things (IIoT) initiatives by enabling rapid deployment of new connected tools and capabilities.
The application's interconnected design means that newly integrated tools or capabilities added for one location automatically transfer to all locations, since the entire enterprise shares one line of software code.
Supported Devices and Technical Requirements
Device Compatibility
Plex Mobile supports a comprehensive range of mobile devices and operating systems to accommodate diverse manufacturing environments:Android Devices: Supports Android versions 10 through 14, with tested compatibility on industrial-grade devices including Honeywell CT60 and CK65, Keyence BTA700, and Zebra TC8300, MC9300, and TC52X.
iOS Devices: Compatible with iOS versions 12, 13, 14, 16, and 17, available through the Apple App Store.
Barcode Scanner Integration: The application works with various barcode scanning solutions, from integrated device scanners to external Bluetooth-connected scanners. Supported devices include Honeywell, Zebra, and Keyence scanners specifically tested for Plex compatibility.
Installation and Access Requirements
Organizations must meet specific technical requirements to utilize Plex Mobile effectively:
Identity and Access Management (IAM) for secure authentication ensures that only authorized personnel can access manufacturing data and controls. Role-based access control (UX) implemented through the Plex platform determines which functions and data each user can access based on their organizational role and responsibilities.
The mobile application is available through standard app stores including Google Play, Apple Store, and Microsoft Store, with Android Package (APK) versions also available for direct installation. A subscription to the Plex Manufacturing Cloud is required, and each business site must have IAM and Plex UX role-based access control properly configured.
Barcode Scanning and Printing Capabilities
Plex Mobile supports comprehensive barcode functionality essential for manufacturing operations:Scanning Capabilities: The application handles both 1D and 2D barcode formats, with support for various encoding standards and designator characters that identify different types of data (quantity, supplier, part numbers, etc.).
Bluetooth Connectivity: Android devices can connect to external barcode scanners via Bluetooth, with scanners configured in Serial Port Profile (SPP) mode to transfer raw text data with carriage returns for each scan. iOS devices do not currently support Bluetooth scanning functionality.
Mobile Printing: Users can print ZPL labels directly from mobile devices using Internet Protocol (IP) printing. The system uses Container Label Logic to determine appropriate label types, with support for default printer assignments by user and session-based printer overrides.
Strategic Implementation Considerations
Change Management and Training
Successful Plex Mobile deployment requires strategic change management to maximize adoption and effectiveness. The application's intuitive, self-guided interface reduces training requirements, but organizations should focus on role-specific training programs that demonstrate how mobile capabilities enhance rather than complicate existing workflows.
Companies report successful implementations within four to six months, with immediate operational benefits visible shortly after go-live. The key success factor involves engaging shop floor workers early in the implementation process to ensure the mobile solution addresses their specific needs and challenges.
Scalability and Future-Proofing
Plex Mobile's cloud-native architecture provides inherent scalability for growing manufacturing operations. The platform's agile development methodology ensures continuous feature updates without disruptive version upgrades. This approach allows manufacturers to benefit from ongoing innovation without the traditional costs and complications of system upgrades.
Organizations planning for future growth can leverage Plex Mobile's modular approach, starting with core inventory and production management capabilities and expanding to include advanced features like AI-powered analytics, IoT device integration, and enhanced collaboration tools as business needs evolve.
Return on Investment and Performance Metrics
Sources:
| Source Title | Publisher | Publication Date | Source Type | Key Statistics/Findings |
|---|---|---|---|---|
| Plex Extends Shop Floor Mobility with Plex Mobile App | Plex/Rockwell Automation | 2018-05-15 | Press Release/News | Mobile app enables role-based menus, real-time data capture with native device capabilities (camera, audio, Bluetooth) |
| Plex Mobile | Rockwell Automation | Rockwell Automation | 2025-08-18 | Product Documentation |
| The Power of Mobile ERP: 3 Benefits for Manufacturers | Plex Systems | 2016-08-23 | Blog/Article | Eliminates delays from batch processing; provides enterprise-wide data connectivity; supports IIoT integration |
| How Smarter Manufacturing Helped These Companies Beat 2023's Biggest Challenges | Plex/Rockwell Automation | 2024-08-31 | Blog/Research Article | 79% of manufacturers lack complete supply chain solutions; quality is #1 outcome manufacturers seek |
| Kamco Plastics Case Study by Plex Manufacturing ERP | Top10ERP | 2024-01-09 | Case Study | 92%+ elimination of material cost discrepancies; inventory tracking reduced from 6 days/month to few hours; $50K annual savings from improved labeling |
| Plex Mobile Device Support Policy | Rockwell Automation | 2025 | Technical Documentation | Official device compatibility: Honeywell CT60/CK65, Keyence BTA700, Zebra TC8300/MC9300/TC52X tested for Android; iOS versions 12-17 supported |
| Mobility in Manufacturing Offers New Opportunities on the Shop Floor | Plex/Rockwell Automation | 2017-11-20 | Blog/Article | Paper-based processes create competitive disadvantages; manual data entry increases errors and inefficiency |
| Forrester Consulting Study: Achieving 412% ROI with Plex | Plex/Rockwell Automation | 2025-07-07 | Research Report | 412% ROI over 3 years; break-even in less than 6 months; $250K annual inventory waste elimination; $2.5M inventory waste savings |
| Key Takeaways from the 9th Annual State of Smart Manufacturing Report | Plex/Rockwell Automation | 2024-11-03 | Industry Report Analysis | 94% of manufacturers expect to maintain/grow workforce with smart manufacturing; quality is top outcome sought by manufacturers |
| Your Keys to Real-Time Inventory Control | Rockwell Automation | 2025-07-07 | Resource/White Paper | Real-time inventory visibility reduces shortages and overstock; automated tracking enables better demand forecasting |
| Plex Connected Worker | Rockwell Automation | 2025-09-02 | Product Page | 25% productivity increase from embedded collaboration features; integrated Microsoft Teams functionality |
| Plex Systems ROI case study: BestMaid | Nucleus Research | 2023-05-03 | Case Study Report | 185% ROI; 75% reduction in financial close processes; 3% increase in annual sales; eliminated $50K annual mislabeling losses |
