Last updated on 2024年8月11日

How do you ensure inventory accuracy and prevent overstocking in a just-in-time manufacturing setting?

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In a just-in-time (JIT) manufacturing setting, inventory accuracy is critical to prevent overproduction and waste, while ensuring that production can meet demand without delays. JIT, a principle at the heart of Lean Manufacturing, requires a precise balance of inventory to minimize holding costs and reduce overstocking. By keeping inventory levels low, you can save on storage space and reduce the risk of inventory obsolescence. However, this also means that any inaccuracies in inventory can lead to production halts and missed deadlines. So, how do you maintain this delicate balance? Let's explore strategies to ensure inventory accuracy and prevent overstocking in a JIT environment.

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Antonio Julio Junior

Especialista de Processos e Melhoria Contínua
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??Master Black Belt - Storytelling com Dados | MBA: Engenharia da Qualidade | Gest?o de Saúde | Gest?o Empresarial |…

1 Cycle Counts

Cycle counting is a proactive inventory management technique where you count a small subset of inventory on a regular basis. Instead of a disruptive full inventory count, cycle counts can be integrated into daily operations, allowing for continuous monitoring and verification of inventory accuracy. By systematically selecting different items to count, you can quickly identify and correct discrepancies without halting production. This method also helps in understanding the root causes of inventory errors, enabling you to implement corrective actions and improve overall inventory management.

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Antonio Julio Junior

Especialista de Processos e Melhoria Contínua
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Para implementar com sucesso uma contagem cíclica, as empresas devem estabelecer um cronograma regular de contagens, definir quais itens ser?o contados em cada ciclo e garantir que a equipe esteja bem treinada nos procedimentos.

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2 Kanban Systems

Kanban is a visual signaling system that triggers the movement of materials within a JIT setting. It operates on the principle of pull production, where work is only started when there is demand. By using Kanban cards or signals to represent inventory needs, you can easily track consumption and replenish items just as they are needed. This not only prevents overstocking but also ensures that inventory levels are aligned with actual production requirements. The visual nature of Kanban allows for quick communication and response, making it an effective tool for inventory control.

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Antonio Julio Junior

Especialista de Processos e Melhoria Contínua
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Esses aspectos tornam o Kanban uma escolha popular entre empresas que buscam melhorar seus processos produtivos e a gest?o de estoques, especialmente em setores como manufatura, logística e servi?os.

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3 Supplier Partnerships

Strong partnerships with suppliers are essential in a JIT environment. Collaborating closely with your suppliers ensures that they understand your production schedules and are capable of delivering materials in smaller, more frequent batches. This minimizes the need for large inventories and reduces the risk of overstocking. Effective communication and information sharing with suppliers can also lead to improved accuracy in order forecasting and planning, further enhancing inventory precision.

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??Master Black Belt - Storytelling com Dados | MBA: Engenharia da Qualidade | Gest?o de Saúde | Gest?o Empresarial | Engenharia Econ?mica | Professor do Senai Cimatec | Coordenador MBA LSS & OPEX Grupo Voitto
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Uma prática de parceria é o Milk Run acordada com o fornecedor onde contribui consideravelmente para a produtividade de uma empresa, tendo em vista que o controle das reposi??es a base de troca reduz o espa?o por n?o gerar estoques altos, além de melhorar o giro.

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Antonio Julio Junior

Especialista de Processos e Melhoria Contínua
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Ao cultivar essas parcerias, as empresas n?o apenas melhoram suas opera??es JIT, mas também constroem uma rede de fornecedores que pode oferecer vantagens competitivas a longo prazo.

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4 Demand Forecasting

Accurate demand forecasting is the cornerstone of effective JIT inventory management. By analyzing historical data and market trends, you can predict customer demand with greater precision. This allows you to adjust your inventory levels accordingly, reducing the likelihood of overstocking while ensuring you have enough materials on hand to meet production needs. Employing advanced forecasting methods can help you respond to market changes more swiftly and maintain inventory accuracy.

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Antonio Julio Junior

Especialista de Processos e Melhoria Contínua
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A previs?o precisa da demanda é, de fato, fundamental para o gerenciamento eficaz de estoques em um sistema Just-In-Time (JIT), ao adotar uma abordagem baseada em dados, as empresas podem melhorar significativamente sua eficiência operacional.

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5 Real-Time Tracking

Implementing real-time tracking technologies such as barcode scanners or Radio-Frequency Identification (RFID) can significantly improve inventory accuracy. These systems provide instant updates on inventory levels as items move through the production process, allowing for immediate identification of discrepancies. Real-time data ensures that you have an accurate picture of your inventory at all times, facilitating better decision-making and reducing the chances of overstocking.

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?????????????? ?????????? ??????????????????

??Master Black Belt - Storytelling com Dados | MBA: Engenharia da Qualidade | Gest?o de Saúde | Gest?o Empresarial | Engenharia Econ?mica | Professor do Senai Cimatec | Coordenador MBA LSS & OPEX Grupo Voitto
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Um alerta para utiliza??o de tecnologias de rastreamento: Evite ao máximo as formaliza??es de sistemas. Salvo necessidades por quebras de equipamentos, quedas de energia, ou algo parecido. Mas nunca em fun??o do processo! Por exemplo: Se um funcionário deixa gerar lotes para bipagens posteriores a etapa de um processo sem um motivo justo haverá um delay nos lan?amentos e um comprometimento significativo com a paridade físico x contábil do controle de estoque.

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6 Continuous Improvement

Continuous improvement is a fundamental aspect of Lean Manufacturing and applies to inventory management as well. Regularly reviewing and analyzing your inventory processes helps identify inefficiencies and areas for improvement. By fostering a culture of continuous improvement, you can refine your inventory management practices over time, leading to greater accuracy and efficiency. Encouraging feedback from employees who handle inventory can also uncover insights that lead to better control and prevention of overstocking.

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How do you ensure inventory accuracy and prevent overstocking in a just-in-time manufacturing setting?

1

2

3

4

5

6

1 Cycle Counts

2 Kanban Systems

3 Supplier Partnerships

4 Demand Forecasting

5 Real-Time Tracking

6 Continuous Improvement

Lean Manufacturing

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How do you ensure inventory accuracy and prevent overstocking in a just-in-time manufacturing setting?

1

2

3

4

5

6

1 Cycle Counts

2 Kanban Systems

3 Supplier Partnerships

4 Demand Forecasting

5 Real-Time Tracking

6 Continuous Improvement

Lean Manufacturing

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