Since I don't have E-tools nor the Twin Rose campaign suit, PCGEN is the best character generator I have access to, but...
I don't use it (I play with it, watch for its progress however). It's simply faster and simpler to use pen&paper. Why ?
1)The program, despite some recent minor improvment, is simply too slow on most computer, especialy the P100 32 MB available in my club. At home, I have a k6 300 with 128 MB, and it takes five second to just add a new level to a character. So that's at least one minute to just "say" "this character is a level 12 cleric". And with the new castrated version, you must add the time required to specify how many hit point you gain at each level (unless you choose the allways max hit point, there isn't even an "average setting")!
I remember the first version of PCGEN (before the 2.0.0), it was so much faster. And simpler, see below
2)The program is still more complex than necessary. 15 tabs ! That's 5 too much I think. The summary,ability and race tab should be one and the same (just remove prereq and source column, and use the label instead, and you will have the place needed). And I can't see the point of having a description + a misc + a note tabs !
When you lauch PCGEN, the first thing you see is the Source Material tab. Remove it ! For the first use, load the PHB only. And add, in each character tab a "setting" icone wich you can click on to access wich source you use for this tab.
Example : race tab, By default, only the PHB race are available.If you want something more exotic, or if you want to forbid such or such race, click on the setting icone, then select the source material you want to use , then select wich races you want to be available with a check box before each race, click on the OK button, and choose the race of your character. And of course, the next time you start PCGEN, these races will be available in the race tab. You can add a "save config" option in the file menu, so you can have various configurations available (the equivalent of the customize option in the source material tab, but far more intuitive, I think)
The inventory and Equiping tab should be merged (There isn't a spell and a spellbook tab, isn't it ?). And an item should not be available under more than one category (magic.weapon. and weapon.magic.) : It's just confusing.
In the Skill tab, there is no need to have two column for the cost of a skill (in the right and the left part) and since there is a "total" column, there is no need for the "modifier" one.
In all tab, please allow the user to hide the column he doesn't use (by example the source column). The Cost column may be removed, if a color or font code was used.
Last but not least, since it still doesn't work perfectly, and since there is the possibility to print via PDF, why is there still a preview tab ? Remove it, I'm sure a single item in a menu, or a single icon in the toolbar (preview in browser) will be enough. If it can save some memory ressource and speed up the program, it will be better. I know you can hide the preview tab, but I still think it will be best to remove it. And the zip file will have some kb less too...
3)PCGEN still lack some important fonctions
It would be great, when you create a n level character to get the money for a character of n level (see the table in the DMG) : this would be a great option. And why, when you buy a familiar doesn't it appear in the ressource tab ?
There is an obvious lack of communication between the tabs : equiping and inventory, ressource and inventory, spells and inventory (when you have more spells in your spellbook than the standard alotment for your level, these extra spell should have been bought. And BTW a spellbook has 100 page, and you need 2 pages per level of spells : it's another thing PCGEN does not know).
And I don't understand why PCGEN allow you to create monster, while it is so hard to use for creating NPC > I don't need as much detail for an NPC than for a PC, and PCGEN really lack a instant NPC generation tool.
In the skill tab, it will be great if perform did function the same way than speak langage, adding a new art each time you gain a new rank. The possibility to create a new knowledge/profession/craft as you need it (like you create a new magic item by customizing it) would be appreciable.
In the class tab, I would like to see a table, indicating for each level what class you choose. I don't know how PCGEN work for things like max skill and multiclassed character, but I do know that the order you progress in your different classes does affect the skills and feat you may choose.
So, when PCGEN will be faster, more intuitive, when it will be able to generate ability and hit point, when it will use the FR stuff I use, I will use it. Until this time, I play with it, download each new version and wait.
And NO I can't use PCGEN as a replacement for a book I don't have. I recently tried for the psiHB I had forgotten, and it was nearly useless (One of my gamer was able to find what was the prerequisite feat for the metamind, however, so she could take the feat without waiting that I retrieve my book).
And there is the last problem of PCGEN : you can't erase and rewrite a printed character sheet, like you can with a pencil-filled one

(Who print a new sheet each time he level up ?)