As manufacturers modernize their production environments, ensuring compatibility between software platforms and shop-floor hardware is becoming increasingly important. At I I Stanley Co. Inc., a leading US manufacturer of automotive lighting products, the implementation of KEYENCE BT-A600 handheld computers has ensured a smooth transition to the company’s new Plex UX manufacturing platform while simultaneously enhancing scanning performance.
Based in Battle Creek, Michigan, I I Stanley manufactures advanced automotive lighting products for vehicles. A member of the Stanley Electric group, the 600+ employee company continually invests in new technologies to enhance quality, efficiency, and customer service.
“We produce a wide range of automotive lighting products, from headlamps and tail lamps to fog lamps and auxiliary lighting,” explains Peter Patterer, IT manager at I I Stanley. “As a manufacturer, it’s important that we continue investing in the latest technologies for the benefit of our customers.”
Supporting digital transformation
The need for new handheld computers arose during I I Stanley’s migration from the Plex Classic manufacturing platform to the latest Plex UX.
“We upgraded because Plex UX offers a more modern environment with role-based security and guided workflows, as well as a unified interface,” says Patterer. “However, running Plex UX required a newer version of Android than our previous scanners supported. They simply weren’t compatible with the new application, so upgrading our handheld computers became the only practical path forward.”
Following recommendations from its Japanese parent company, which already uses KEYENCE handheld computers, I I Stanley evaluated the BT-A600.
“We carried out trials using multiple BT-A600 handheld computers on two production lines,” he explains. “Everything worked extremely well, so we invested in a fleet of devices for use across our Battle Creek facility.”
Seamless integration with Plex UX
A major advantage of the project was straightforward integration between the BT-A600 handheld computers and Plex UX.
“It was very easy to integrate the devices,” confirms Patterer. “Once we had the Android version, image, and settings configured on one BT-A600, we were able to deploy everything across the entire fleet.”
Patterer believes this flexibility will become increasingly valuable as manufacturing software continues to evolve: “Compatibility can become an issue as software platforms develop over time, particularly with older hardware. The BT-A600 gives us confidence that we’re well-positioned for the future.”
Improving shop-floor productivity
At I I Stanley, KEYENCE BT-A600 handheld computers support activities that include material movement, receiving goods, shipping operations, and production line replenishment. Data captured by the devices feeds directly into the Plex UX for analytics and reporting.
The BT-A600 has also delivered improvements in scanning performance.
“We’ve found the scanning range to be significantly better than our previous devices. Operators can capture data from greater distances, which is particularly useful when materials or finished products are stored at height.”
The enhanced scanning capability will become even more valuable as I I Stanley prepares to adopt 2D barcode technology.
“We’re currently transitioning toward 2D labels because they allow much more information to be stored within a single code. The ability to scan quickly from extended distances will further improve efficiency.”
Centralized fleet management
To support its growing fleet of KEYENCE BT-A600 handheld computers, I I Stanley implemented SupplyPoint vending machines that improve device accountability and availability.
“Each employee checks a scanner in and out using their ID badge to provide complete accountability,” explains Patterer. “The system automatically issues the device that has been residing in the vending machine the longest, ensuring operators receive one with the highest available battery charge.”
I I Stanley also leverages Hexnode UEM (unified endpoint management) to remotely configure, update, and monitor all BT-A600 handheld computers from a central location, reducing manual setup time while helping maintain consistency across operations.
Investing for the future
Alongside the technology itself, Patterer highlights the support received throughout the project:
“Our local KEYENCE representative has proved extremely responsive and knowledgeable. They have been a great resource.”
Looking ahead, Patterer believes investments in new technologies will continue to strengthen I I Stanley’s competitive position.
“Our customers demand complete product accuracy and on-time delivery, so investing in technologies like the KEYENCE BT-A600 demonstrates our commitment to meeting those expectations,” he concludes. “It’s helping us build stronger customer relationships, win new business, and support the continued growth of our Battle Creek operation.”
