THE PROJECT
The Challenge:
- Inconsistent PDP standards across global plants
- 40 part numbers increased sourcing complexity
- Needed one repeatable solution for 52 facilities
The Solution:
- Standardized Rittal TS 8-based PDP
- 40 part numbers consolidated into one configuration
- Eplan engineering + Rittal automated machining
Introduction
Automotive manufacturers depend on a global network of OEMs, system integrators, and suppliers to keep production moving, but when every partner works from different standards, complexity grows quickly.
For one major North American automotive manufacturer, the challenge was to create a power distribution panel architecture that could be repeated across 52 facilities worldwide without sacrificing local support, engineering flexibility, or speed.
Electro-Matic worked with Rittal and Eplan to develop a standardized power distribution panel solution that combines modular enclosure technology, automated machining, and digital engineering into one globally repeatable system.
About Electro-Matic
Electro-Matic is an industrial automation solutions provider serving manufacturers with automation, control, and power distribution technologies. A longtime Rittal and Eplan partner, Electro-Matic has invested in both digital engineering and automated enclosure modification capabilities to help customers design, manufacture, and deploy customized control solutions faster and with greater consistency.
The Challenge
The automotive manufacturer works with OEMs and system integrators around the world to support its assembly operations. Over time, those different partners introduced different standards, suppliers, parts, and panel configurations that created global complexity.
The customer needed a way to:
- Standardize power distribution panels across plants
- Reduce the number of parts and suppliers involved
- Make outsourced projects easier to repeat and scale
- Simplify engineering changes and documentation
- Maintain reliable product availability for future builds
The goal was to create a global standard that local OEMs and integrators could reproduce consistently.
The Rittal Solution
By partnering with Rittal and Eplan, Electro-Matic developed a fully assembled power distribution panel based on a modified Rittal TS 8 modular enclosure.
Instead of managing 40 unique part numbers, the customer can order a single configurable product built to its specification, which dramatically simplifies sourcing while making programs outsourced to local OEMs easier to repeat across global facilities.
Eplan houses the engineering documentation and component data behind the design. Bill of materials information, CAD data, schematics, and other engineering details remain connected to the project, making downstream changes easier to manage.
That connected component data also reduces the manual work required to build out the design.
“One of the beautiful things about Eplan is the database of base component parts. Instead of having to look for all the CAD data of widgets that go into assembly, you just upload a bill of materials and all the data will get populated automatically.”
Rittal Automation Systems adds another layer of repeatability.
Electro-Matic uses Rittal Perforex automated machining centers to modify and customize enclosures with greater speed, precision, and consistency than traditional manual machining.
Together, the system connects the following processes into a single, cohesive, repeatable ecosystem:
- Standardized Rittal enclosure infrastructure
- Automated enclosure machining
- Eplan Pro Panel engineering and 3D design
- Centralized BOMs and documentation
- Repeatable manufacturing across multiple locations
The Implementation
Electro-Matic was one of the first Rittal partners in North America to offer local enclosure modification using the Rittal Perforex. Today, Electro-Matic operates three Perforex machines—two at its Metro Detroit facility and one in Cleveland—giving its engineering and production teams greater capacity for fast, precise enclosure modification.
“With the utilization of Rittal Automated Systems, Electro-Matic has the technology and expertise to modify, assemble, and customize enclosures to meet our customer needs. We depend on our engineering team and the Rittal Perforex machine to automate this process. These tools give us the ability to machine custom enclosures with precision and accuracy — and much faster than traditional hand-cutting methods.”
“Across the board, customers love that we can offer this value-add service,” says Groden. “It saves them time and money while preventing errors, and it allows us to be more flexible to meet our customers’ needs.”
Eplan Pro Panel supports the manufacturing process with 3D panel design, collision checking, thermal considerations, component data, and documentation.
That digital foundation extends beyond design into sourcing and manufacturing documentation.
“But it’s not just about the upfront engineering time or the documentation that is needed for manufacturing,” explains Ken Hady, Strategic Account Manager for Eplan. “Eplan software brings in sourcing, how the documentation is being managed, and how you are storing the bill of materials.”
Rittal and Electro-Matic also established transparent monthly forecasting with the automotive customer. Forecast data helps Rittal maintain availability of the specific enclosures and accessories Electro-Matic needs for upcoming PDP builds, which reduces the risk of supply-related production interruptions.
The Results
The combined solution created several measurable improvements in standardization, engineering, manufacturing, and global support:
- 40 Part Numbers Reduced to One Configurable Solution: Simplifies sourcing, ordering, and repeatability
- 52 Manufacturing Facilities Supported: One standardized PDP architecture can be deployed across the customer's global manufacturing network
- Faster Enclosure & Panel Modification: Automated machining replaces slower manual cutting and modification processes
- Faster Engineering Cycles: Reusable digital engineering data reduces the need to recreate designs and component information
- Reduced Error Risk: Eplan Pro Panel supports precise 3D design, collision checking, thermal planning, and manufacturing documentation
- Lower Change-Order Risk: Better engineering accuracy helps reduce costly build errors and downstream corrections
- Simplified Spare Parts and Sourcing: Standardization reduces the number of unique components the customer must manage
- Greater Global Scalability: Local OEM and integrator projects can begin from an established architecture
- Improved Service Response: Digital documentation and Rittal's global network enable faster troubleshooting and localized support
The value became especially clear when unexpected issues occurred.
In one urgent situation, a Rittal account manager personally transported enclosure doors to Electro-Matic for modification and returned them so the customer's critical system could go live as planned.
“This is not a normal process,” says Groden, “but in an emergency-down situation, we accommodate urgent requests because we have local CNC capabilities.”
In another case, a completed PDP was damaged while being shipped to a facility in China. Rather than replacing the entire panel and delaying the project, Electro-Matic and Rittal coordinated with local Rittal resources in China to provide a local modification solution.
Because the design was documented in Eplan, the team could identify the damaged component from the schematic and bill of material and determine exactly what needed to be replaced.
“Because Eplan is so organized and documents everything precisely, the customer was able to tell us exactly which component was damaged and what needed replacing,” says Groden. “We pulled up the schematic, looked at the bill of materials, and were able to pinpoint exactly what they needed.”
Nicole Brecht, Global Key Account Manager at Rittal, says the global support model is just as important when unexpected problems arise.
“We know there are going to be problems that arise,” says Nicole Brecht, Global Key Account Manager for Rittal. “That is a matter of fact with life, but it’s how you resolve those problems that people will remember. We could have said, ‘That’s not our problem, file a shipping claim.’ But Rittal’s mission is to provide a total package solution for our customers. In this case, because Rittal is a global company, we were able to do that seamlessly.”
Conclusion
Global standardization requires connecting engineering, sourcing, manufacturing, documentation, and service so successful designs can be repeated wherever production expands. By combining Electro-Matic's automation expertise with Rittal enclosure and automation technology and Eplan digital engineering, the customer gained a standardized power distribution solution that is easier to engineer, source, manufacture, modify, and support across 52 facilities worldwide. The result is a more repeatable manufacturing ecosystem built to reduce complexity and accelerate deployment.