Case Study: Green Tokai achieves real-time visibility, improved quality, and streamlined inventory control with Plex Systems ERP

Green Tokai Strengthens Visibility, Quality, and Inventory With Real-time Data in Plex Erp

Green Tokai Co. (GTC), a maker of automotive door and window seals and moldings with plants in Brookville, OH and Maysville, KY, was operating on a largely paper‑based, low‑tech system—clipboards, spreadsheets and a back‑office ERP with limited shop‑floor PCs. That setup produced delayed production reporting, fragmented quality tracking and poor inventory traceability, prompting GTC to seek a modern ERP to provide real‑time data and a single source of truth.

GTC chose Plex (with implementation partner Revolution Group) and went live on June 1, 2023; the rollout added shop‑floor PCs, replaced paper workflows, and enabled real‑time production reporting and OEE monitoring. Plex delivered serialized inventory, smarter cycle counts and location tracking, stronger quality traceability, and greater operational agility—results GTC is building on as it phases out spreadsheets and extends Plex into maintenance and quality.

Green Tokai

Joseph Daniel

General Manager of Erp & Finance