For manufacturers running Plex ERP, Excel continues to be a critical but problematic tool in managing supply chain operations. While Plex provides cloud-based ERP and MES capabilities, many supply chain teams still rely on spreadsheets for:

• Supplier collaboration and purchase order tracking

• Demand planning and inventory adjustments

• Production scheduling overrides and capacity planning

• Custom reports and data aggregation from multiple sources

The proliferation of Excel is driven by complex and global supply chains and the need to fill the functional gap between Plex ERP modules and business requirements.

While Excel is flexible, it also introduces delays, errors, inefficiencies, and version-control nightmares—slowing down operations and increasing costs.

Enter Boardwalk Velocity, a structured collaboration platform that eliminates the Excel bottlenecks in manufacturing supply chains, resulting in:
✅ 70-80% efficiency gains
✅ 2-4% improvement in profit margins
✅ Reduction in duplicate supplier orders
✅ Better inventory control, reducing obsolete parts
✅ Improved forecasting and capacity utilization
✅ Higher revenue, better customer satisfaction, and talent retention

By replacing Excel-driven processes with real-time, structured collaboration, Boardwalk Velocity helps manufacturers streamline operations, cut millions in costs, and drive profitability.

Why Excel Persists in Manufacturing Supply Chains Despite Plex ERP

Even with a modern ERP like Plex, manufacturers continue to rely on Excel because:

1. Supplier Collaboration is Disconnected

Plex provides limited real-time collaboration tools, so procurement teams use Excel to manage purchase orders, lead time adjustments, and supplier commitments. This results in:
❌ Multiple versions of the same PO circulating via email
❌ Mismatches between supplier deliveries and production needs
❌ Duplicate orders and costly inventory build-ups

2. Demand & Supply Planning Requires Manual Workarounds

Plex’s MRP and forecasting tools often don’t account for rapid changes in demand, supply chain disruptions, or manual overrides needed for last-minute adjustments. To compensate, planners:

• Export data into Excel for offline scenario planning

• Make manual adjustments to inventory projections

• Struggle to sync changes back into Plex

This lack of real-time planning creates bottlenecks, resulting in:
📉 Overproduction or stockouts
📉 Increased carrying costs for excess inventory
📉 Missed customer delivery deadlines

3. Production Schedules Lack Real-Time Data Updates

Manufacturers rely on Excel for work center scheduling, capacity adjustments, and shift planning because Plex’s native scheduling doesn’t always provide the flexibility needed for:

• Late supplier shipments and material delays

• Unplanned equipment downtime

• Last-minute order changes from customers

Since these adjustments are made outside of Plex, they don’t update the ERP in real-time, causing inefficiencies on the shop floor.

4. Disconnected Reporting Leads to Poor Decision-Making

Manufacturers frequently pull data from Plex into Excel to consolidate it with:
📊 Supplier reports
📊 Logistics provider updates
📊 Market demand forecasts

This manual process leads to:
❌ Errors due to outdated or duplicate data
❌ Delayed decision-making
❌ Siloed teams working with inconsistent information  

How Boardwalk Velocity Eliminates Excel Bottlenecks in Manufacturing

Boardwalk Velocity acts as a real-time collaboration layer for Plex ERP, providing structured data management and automated workflows while preserving Excel’s flexibility.

1. 70-80% Efficiency Gains with Real-Time Data Synchronization

🚀 No more manual exports, emails, or version conflicts—Velocity connects directly to Plex, ensuring that every update is reflected across all users in real time.
🚀 Faster planning cycles and reduced administrative overhead free up teams to focus on higher-value tasks.

2. 2-4% Profit Margin Improvement Through Smarter Decision-Making

✅ Lower operating costs by reducing manual data handling and spreadsheet-based errors.
✅ Better inventory accuracy ensures optimal stock levels, reducing waste and write-offs.
✅ More efficient supplier collaboration results in fewer disruptions and cost overruns.

3. Reduction in Duplicate Supplier Orders

📉 Procurement teams get real-time visibility into orders, lead times, and supplier commitments—preventing double ordering and excess inventory accumulation.
📉 Automated supplier confirmations ensure accuracy, eliminating back-and-forth email corrections.

4. Elimination of Obsolete Parts Inventory with Order Variance Detection

⚙️ Detects discrepancies in demand forecasts, supplier orders, and inventory levels before they cause overproduction or obsolescence.
⚙️ Reduces deadstock and holding costs—improving working capital efficiency.

5. Improved Forecasting & Capacity Utilization for Revenue Growth

📈 More accurate supply chain data ensures optimal production scheduling, leading to:
✔ Higher on-time delivery rates
✔ Better utilization of labor, equipment, and materials
✔ Reduced lead times and increased throughput

These improvements drive higher revenue and stronger customer satisfaction.

6. Stronger Talent Retention & Workforce Productivity

🔹 Eliminates spreadsheet-driven inefficiencies, reducing frustration for supply chain and production teams.
🔹 Allows employees to focus on strategic decision-making instead of data entry.
🔹 Boosts job satisfaction, retention, and performance in an industry facing labor shortages and skills gaps.

The Future of Manufacturing Supply Chains: Digital, Connected, and Scalable

For manufacturers using Plex ERP, Boardwalk Velocity delivers a smarter, faster, and more connected supply chain—without the burden of Excel-based workarounds.

🚀 The Bottom-Line Benefits:

✔ 70-80% efficiency gains
✔ 2-4% increase in margins
✔ Reduction in duplicate supplier orders
✔ Lower obsolete inventory costs
✔ Better forecasting and capacity utilization
✔ Higher revenue, improved customer satisfaction, and better talent retention

By replacing Excel-driven chaos with real-time data synchronization, structured collaboration, and automated workflows, Boardwalk Velocity empowers manufacturers to reduce costs, increase productivity, and enhance profitability—all while making supply chain teams more effective and agile.

🔗 Ready to take your Plex ERP supply chain to the next level?

Learn how Boardwalk Velocity can help your manufacturing operations streamline workflows, eliminate inefficiencies, and drive profitability.