The Challenge: Manual Processes and Siloed Information

Before implementing EXACT Track, Stubbe’s Precast relied heavily on manual data entry supported by digital tools and a patchwork of Excel spreadsheets to manage critical operations. While this approach was functional, it created several key challenges:

• Time-consuming data entry and calculations: Teams spent considerable time extracting data into Excel, manually calculating results, and stitching together datasets from multiple databases. This process was slow, inefficient, and prone to errors.
• Lack of real-time visibility: Although Stubbe’s built their own Excel-based system for analysis, the siloed nature of the data made it difficult to gain a holistic view across plants. For example, linking rebar heat numbers, concrete data, and defect tracking back to individual elements required significant manual effort.
• Fragmented defect tracking: While defects were digitally logged on the floor, data was later downloaded into spreadsheets for resolutions to be issued from their engineering team and for monitoring and analysis. Refreshing large datasets in Excel consumed valuable time and delayed response to issues.
• Limited data for informed decision-making: With reporting heavily dependent on manual processes, opportunities for optimization were often identified too late, or missed entirely

The Solution: A Unified, Digital Platform with EXACT Track

Stubbe’s Precast recognized an opportunity to replace their patchwork tools with a unified system—one that not only streamlines current processes but also unlocks greater data visibility, tracking, and future opportunities for efficiency and optimization.. Following an initial connection at a CPCI conference in 2019, they fully embraced EXACT Track in August of 2024. Our team worked closely with Stubbe’s, and specifically their Quality Assurance Manager Steven, to understand their unique workflows and translate their needs into tailored features with implementation in the first half of 2025.

Key Implementations and Features:

• Centralized Defect Management: A dedicated defect module was created, allowing Stubbe’s to capture, quantify, and track issues as they occur across all their plants in real time. This provides a clear, high-level overview of defects and helps streamline remedial actions in real time. In addition, Stubbe’s is looking at extracting element information out of EXACT to place elements that have a defect that is unresolved on “QC hold” in their other digital systems automatically so that pieces do not get shipped until all defects are resolved. 
• Concrete Information & Monitoring: Stubbe’s now captures all concrete information within EXACT Track. By leveraging their existing Forney Vault system alongside our concrete temperature monitoring capabilities, they can know precisely when hollowcore and other elements hit their target strength. In addition, linking the elements poured with that concrete batch the concrete testing information and strengths are instantly linked to each element and accessible within seconds. 
• API Integrations: EXACT built custom APIs to seamlessly integrate with Stubbe’s existing systems, such as their scheduling software and drawing management. Drawings are imported automatically, triggering the creation of all elements in EXACT, complete with digital copies, without any manual input. QC staff now carry tablets with digital drawings that can be marked up in real time, eliminating paper reliance and enabling instant collaboration.
• Unified Platform for All Plants: EXACT Track consolidates data from all of Stubbe’s plants into a single, easily navigated platform, providing management and engineering with the real-time visibility and history of every element produced. 

The Collaborative Process: A Partnership in Innovation

EXACT’s engagement with Stubbe’s Precast has been a true collaboration. The EXACT Track team spent significant time on-site, observing their processes and conducting immersive discovery meetings. This approach was crucial for understanding the nuances of their operations, particularly their stressing process.

Steven, Stubbe’s Quality Assurance Manager, was a key stakeholder and an invaluable partner throughout the development process. His direct involvement and willingness to embrace digital transformation were essential. EXACT held meetings with him and our software team to discuss designs, ensuring the solutions met their specific needs while also considering broader applicability for our other clients.

Project Outcomes

• One unified platform for different plants, creating a single source of truth.
• Countless hours saved in data entry and administrative work.
• Fully digitized QC with QC checks and results instantly accessible across teams
• Improved traceability with every element linked to its QC data, concrete results, and defect history

The implementation of EXACT Track is already delivering significant value to Stubbe’s Precast. By automating processes that were once a mix of manual entry, digital tools, and spreadsheet linkages, Stubbe’s is saving countless hours while minimizing human error. With all data consolidated in one system, traceability has greatly improved, enabling engineering teams to quickly assess the impact of changes, such as loading adjustments, on individual elements.

Steven, in particular, values the ability to track and consolidate all data in one place without relying on Excel to link disparate databases. The dedicated defect module also provides precise quantification of issues, enabling faster and more effective resolutions. This digital transformation has empowered Stubbe’s to monitor remedial processes and make truly data-driven decisions that were previously out of reach.

What’s Next for Stubbe’s Precast

Stubbe’s Precast is already seeing the benefits of EXACT Track and is eager to expand its use. They plan to integrate more plants and sections of their company into the platform, a clear indication of their satisfaction and the value they derive. This ongoing partnership highlights our commitment to developing solutions that not only meet immediate client needs but also evolve with their growth and industry demands.

Stressing Module Automation: EXACT is finalizing the design to roll out a custom stressing module within EXACT Track. This module mirrors the functionality of Excel but is seamlessly integrated into the platform, automating calculations, centralizing all stressing-related data, and improving safety by minimizing manual intervention in critical processes. 

We are excited to share this with our other prestressed precast clients.