ERP Real-Time Data Improves Green Tokai Visibility

Green Tokai (GTC) began operating in May of 1988. Since then, the global company has expanded to include three additional plants in Brookville, OH and one production facility in Maysville, KY. GTC was operating within a low-tech framework, relying predominantly on two software systems alongside Excel spreadsheets. Shop-floor activities were conducted manually, with clipboards and paper serving as the primary tools for coordinating the company’s work centers. Production reporting was also paper-based, leading to delays in data entry within the existing ERP framework.

Additionally, many GTC work centers lacked PC infrastructure, hindering digital integration and access to real-time data. Despite sporadic usage, the ERP system in place primarily served back-office functions, which resulted in a lack of linkage between master data and operational outputs. GTC also faced several challenges that impacted operations. For example, limited inventory tracking and management capabilities decreased the company’s ability to maintain accurate stock levels. The lack of real-time data resulted in operational inefficiencies and impacted timely decision-making. Quality tracking was also fragmented, relying on a combination of customer portals and spreadsheets. Manual documentation of quality checks on paper further complicated analysis and retrieval processes, despite meeting basic requirements.

Choosing Plex

Driven by these challenges, GTC initiated the search for a new ERP system. The company recognized the need for real-time data to enhance visibility and establish a single source of truth across its operations. Moreover, industry trends, including an increase in customer demand for serial traceability and quality tracking, emphasized the urgency for a comprehensive solution.

Plex emerged as the preferred choice for GTC’s new ERP system after a recommendation from a customer. Plex’s cost structure and endorsement by a significant industry player made it a compelling solution to address the company’s challenges.

Company-Wide Preparation and Successful Implementation

Successful adoption was a top priority for the entire GTC team throughout the implementation process. To enhance awareness, flyers were distributed extensively before the Plex implementation began and regular weekly meetings with department managers were held. Hands-on involvement in configuration, design, and training discussions also allowed Green Tokai team members to grasp the benefits of Plex well before implementation began.

Implementation involved multiple departments and individuals across the organization alongside Plex Implementation Partner, Revolution Group. Initially, a core team of approximately six members spearheaded the implementation process before it was extended across all 13 departments, each with designated primary and secondary super users. These super users were responsible for coordinating departmental activities, conducting training sessions, and ensuring readiness for implementation across all GTC plants.

Team leaders overseeing various work centers also ensured that their operators received adequate training. Post-implementation, these operators have demonstrated immense resourcefulness, exploring system functionalities beyond their initial training. GTC successfully implemented Plex and went live on June 1, 2023.