Why Patchwork Planning is Costing Retailers up to $140B in Lost Sales

Merchandising is Only Getting More Complex

Forecast accurately. Hit margin goals. React fast. Align cross-functionally. And do it all while managing store rollouts, drops, and collaborations.

But if your team still runs planning on spreadsheets or legacy systems, you’re stuck wasting hours every week building plans from scratch and fixing bad data before you can even get to analysis. That approach might get you through the season, but it doesn’t scale, and doesn’t catch risk before it eats into margins.

Disconnected planning doesn’t just slow teams down, it directly impacts the bottom line. Fashion retailers overproduced more than 5 billion units last year due to poor planning visibility, resulting in $140 billion in lost sales.1.(Retail Dive) Speed, not strategy change, is what separates successful planning teams. Getting the right data, fast, without rebuilding from scratch.

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Data-Rich, Decision-Poor: The Planning Gap Costing Retailers Millions

Legacy tools and spreadsheets are slowing retail planning. Toolio connects your data, accelerates decisions, and protects millions in revenue.

The Problem: Friction That Slows Everything Down

Merchandisers lose time and confidence every week to the same issues:

Manual reforecasting: No easy way to update plans, so teams start from scratch in Excel

Too much formatting, not enough insight: Stitching together data becomes the job

Collections and drops live ‘off-system’: Special plans for collaborations, etc. get messy and error-prone

Misalignment across teams: Finance, buying, allocation all work off different numbers

Workarounds everywhere: When tools can’t flex, people do at the cost of control

AI for Every Role, Insights for Every Goal

What’s at Risk?

Slow, error-prone planning doesn’t just waste time, it puts the business at risk:

Forecast misses: stockouts, markdowns, lost margin

Siloed systems: conflicting data, misalignment

Lack of agility: can’t react to shifts fast enough

Dirty data / inconsistent view: teams don’t trust what they see

$140B

In lost sales from brands producing up to 5B of excess stock

20%

Average monthly profit lost from size forecasting errors

75%

Of retail execs cite data-driven planning and forecasting their top priority

Source: BoF The State of Fashion 2025

The Fix: Planning Efficiency That Puts You Back in Control

Toolio helps you reclaim hours every week, make faster decisions, and stay ahead of shifting demand. Gain control over your calendar, your buys, and your margins.


Here’s the impact of modern planning, side-by-side:

Manual Planning
With Toolio
Teams work from conflicting versions of spreadsheets
One source of truth - everyone plans off the same data
Reforecasting takes hours and requires rebuilding plans
Real-time reforecasting - update plans instantly, no rebuilds
Drops and capsules are managed off-system or in workarounds
Collection-ready workflows - plan drops without workarounds
Tabs duplicated to track seasonal or weekly changes
Retail calendar + versioning - no need to duplicate tabs
Plans based on outdated data and delayed actuals
Live actuals integration - plan with today's data

How to Spot Inefficiencies and Start Fixing Them

1. Measure Your Planning Time

  • How many hours go into formatting or stitching data together?

  • How long does it take to reforecast after a macro shift or markdown decision?

2. Map the Workarounds

  • Are you using spreadsheets outside of your planning tools?

  • Are you still managing markdowns or product drops over email?

3. Flag High-Stakes Planning Moments

Where does your current system make these harder than they should be?

  • In-season pivots

  • Seasonal builds

  • Key buy reviews

4. Talk to Your Cross-Functional Teams

  • Where are misalignments showing up downstream?

  • What’s the cost of not planning from the same set of numbers?

5. Bring Value to Life with a Real-World Demo

You don’t need a full implementation to see how Toolio improves planning. See the impact through live, guided demos tailored to real use cases: like reforecasting speed, assortment complexity, or planning around drops and collabs.

Let the platform speak for itself.

  • Retail-native templates built for merchandise planning, not just grids and cells

  • Real-time scenario modeling so you can pivot fast without starting over

  • Clean integration of sales actuals to keep every plan grounded in reality

  • Dynamic views and workflows that reflect how merch teams actually operate today

Customer Success: Magnolia Cuts Planning Time by 67% with Toolio

Before Toolio, Magnolia’s planning team juggled Excel, Domo, and NetSuite just to stay on top of inventory. The process was slow, manual, and fragmented. Reforecasting took hours. Visibility was limited. Decisions lagged behind sales trends.

With Toolio, they replaced all of that with one integrated platform.

Planning time dropped from 15 hours to 5 per week

Total efficiency improved by 30%

Inventory turnover increased, while stockouts decreased

Craig Smith

Sr. Merchandise Planner

“Being able to see a forward forecast has been especially beneficial in reacting to sales trends and staying in stock on items that are overperforming.”

What Changed?

  • One source of truth: Magnolia now plans, forecasts, and replenishes in Toolio with every team working from the same data

  • Faster decisions: Real-time visibility helps them act on trends before issues grow

  • Smarter purchasing: They’ve shifted from bulk buys to demand-aligned orders, improving cash flow and availability

Magnolia’s results show what’s possible when planning becomes faster, clearer, and grounded in real-time data.

Read more Customer Stories

Faster, More Accurate Planning with Toolio

Toolio doesn’t just speed up planning. It helps reduce stockouts, lower holding costs, and improve margins by turning reactive guesswork into proactive strategy.

AI-powered forecasting: More accurate demand = less overstock

Integrated platform: One plan across buying, finance, stores

Real-time collaboration: No more siloed teams or version control issues

Scenario planning: Model “what if” and act faster

Workflow automation: Less manual work = more time for strategy

AI for Every Role, Insights for Every Goal

2-3%

Margin Improvement

5-10%

Increased In-Stock Rate

5-10%

Turn Improvement

35%

Time Saving

10x

Return on Investments

You’re Not Just Saving Time, You’re Elevating Your Role

Planning faster means more than saving time. It means you can respond to the business faster, protect margin, and guide strategy with confidence.

Make strategic calls with confidence

Align your team and your business

Stay ahead of demand and competition

Hit your targets and explain how you did it

Merchandise Plan

See Toolio In Action

The best way to understand what Toolio could do for you is to see for yourself. Get started with our team today!