Green Tokai Strengthens Visibility, Quality, and Inventory with Real-Time Data in Plex ERP

A Campaign for Success

Successful adoption was a top priority for the entire 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 to ensure that progress updates were readily available. 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.

Green Tokai’s Plex 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 and, post-implementation, these operators have demonstrated immense resourcefulness, exploring system functionalities beyond their initial training.

Reflecting on their implementation experience, Green Tokai identified areas they would handle differently when approaching the process again. Looking back, Green Tokai wishes they would have provided more time for shop-floor associates to undergo training. It was anticipated that there would be a company-wide learning curve as the dust settled after the implementation. Even with the learning curve, Green Tokai successfully implemented Plex and went live on June 1, 2023.

Immediate Improvements & Looking Ahead

The adoption of Plex brought about significant improvements within Green Tokai’s operations. The transition itself necessitated an upgrade in infrastructure, which led to an increase in PCs on the shop floor. This not only replaced many of the existing paper-based processes, but it also increased general optics for shop floor associates. The utilization of the Plex Control Panel also enabled Green Tokai’s operators to access real-time production reporting, enhancing visibility and allowing for the measurement of operational success metrics such as Overall Equipment Effectiveness (OEE).

With Plex, GTC has transitioned to a culture of continuous improvement. Increased visibility and traceability have facilitated enhancements based on real-time data, fostering a more proactive approach to problem-solving and allowing for more timely business decisions. The transition from a manual, paper-based system to Plex has empowered GTC to respond promptly to the needs of its suppliers and customers, enhancing operational agility and overall competitiveness in the market.

Additionally, Plex facilitated serialization across all inventory levels, enabling better inventory management through intelligent cycle counts and location tracking. Green Tokai now attaches documents to transactions, providing assurance of transaction accuracy.

“The fact that we have real-time data is only starting to reap benefits in other areas,” stated Joseph Daniel, General Manager of ERP & Finance at Green Tokai. “GTC was so used to not having real-time data that we’re only now starting to run several subledger reports… to get a better understanding of how to address issues that impact our results.”

As GTC continues to tap into real-time data with Plex, the team has plans to continue discovering their new ERP system’s full potential. Green Tokai is eager to implement Plex’s Maintenance Module and GTC’s Quality Division is seeking new ways to utilize Plex and continue to phase out paper files and Excel documents every day.

Green Tokai recognizes that success with Plex lies not only in the technology itself, but also in the strategic planning and collaborative efforts with team members and a strong third-party like Revolution Group. Daniel stated, “The true benefits of Plex may only become apparent after going live, emphasizing the importance of a long-term vision and diligent testing.”