How POLYWOOD Scaled Manufacturing Operations with Acumatica

As manufacturing companies grow, the systems and processes that once worked well can quickly become barriers to efficiency.

Manual workarounds.
Disconnected systems.
Limited visibility into operations.

For POLYWOOD, a manufacturer of sustainable outdoor furniture made from recycled plastics, rapid growth exposed the limitations of its legacy systems and highlighted the need for a more scalable solution.

A Company Experiencing Rapid Growth

Over the past decade, POLYWOOD experienced remarkable growth, expanding its operations, workforce, and manufacturing capacity. The company invested more than $100 million into new facilities, doubling both furniture and recycling plant capacities.

When the pandemic hit, demand surged dramatically.

According to POLYWOOD’s Executive Vice President of Information Systems, the company sold three months’ worth of capacity in a single weekend.

But while the business was growing rapidly, its systems struggled to keep up.

The Challenges of Legacy Systems

POLYWOOD relied on a legacy ERP system for financials while many other processes were managed through spreadsheets, paper-based systems, and disconnected applications.

This created significant operational challenges, including:

• Difficulty tracking inventory and production

• Delayed order processing

• Manual scheduling through printed spreadsheets

• Shipping inefficiencies

• Limited visibility into real-time operations

At one point, warehouse operations depended heavily on the knowledge of only a few employees. If they could not locate products, no one could.

As transaction volume increased, the company’s legacy ERP system also began experiencing performance issues and user limitations.

The company needed a modern platform capable of supporting continued growth.

Why POLYWOOD Chose Acumatica

POLYWOOD needed a flexible, cloud-based ERP platform that could integrate with its custom manufacturing systems and scale alongside the business.

After evaluating options, the company selected Acumatica Manufacturing Edition because of its:

• Real-time visibility

• Open API flexibility

• Scalability

• Cloud-based accessibility

• User-friendly licensing model

Unlike many traditional ERP platforms, Acumatica’s licensing structure allowed POLYWOOD to continue growing without worrying about costly per-user fees.

The Results

After implementing Acumatica, POLYWOOD significantly improved operational efficiency across the organization.

Key improvements included:

• Faster financial close processes

• Improved shipping times

• Streamlined order processing

• Real-time data visibility

• Automated workflows

• Reduced manual processes

The company also eliminated many of the operational bottlenecks that previously required office staff to assist warehouse teams during peak seasons.

With Acumatica, POLYWOOD gained a stable platform that allowed its technology team to focus on improving the business instead of constantly fixing system issues.

As POLYWOOD’s ERP Systems Manager explained:

“Acumatica provides the data in real time to the individuals that need it.”

Building a Foundation for Future Growth

Today, POLYWOOD continues expanding its operations, product lines, and market reach with a technology platform designed to scale alongside the business.

Its success story highlights a challenge many manufacturers face:

The systems that supported past growth may not be capable of supporting future growth.

Modern ERP platforms like Acumatica help manufacturers improve visibility, streamline operations, reduce manual work, and create a stronger foundation for long-term scalability.

Modernizing Manufacturing Operations

At HOOPS, we help manufacturers implement Acumatica with a hands-on approach designed to support long-term success.

From evaluating current workflows to implementation, training, and ongoing support, we help businesses modernize operations and build systems that scale with growth.

As manufacturing companies continue evolving, having the right technology foundation has never been more important.