Case Study: TCHO cuts days of supply 63% and boosts production 50%+ with Plex DemandCaster (Plex Systems)

TCHO Achieves Sweet Planning Success with Plex DemandCaster Supply Chain Planning

TCHO, a Berkeley-based maker of premium chocolates with a wide range of SKUs and long raw-material lead times, was struggling with reactive, short‑term production planning that led to stockouts, wasted inventory, and threatened customer relationships. With production schedules set only a week or two ahead and limited MRP and ERP integration, the company needed better visibility and planning to manage perishable finished goods and fluctuating demand.

By implementing Plex DemandCaster with two‑way NetSuite integration and robust MRP/forecasting, TCHO gained proactive inventory control, clearer visibility into demand, and streamlined work‑order generation. The result: on‑time shipments improved nearly 20%, production rose over 50% while maintaining/exceeding a 98.5% service level, critical stockouts fell more than fourfold, and finished‑goods days of supply dropped 63%.

TCHO

Janet Poeschl

Senior Vice President, Supply Chain and Innovation