Inventory discrepancies are a common and costly problem for food manufacturers. They can affect production planning, quality control, customer satisfaction, and profitability. In this article, you will learn what inventory discrepancies are, why they occur, how to measure them, and what are the most effective ways to track and report them.
Inventory discrepancies are the differences between the actual and recorded quantities of raw materials, work-in-progress, finished goods, or packaging materials in a food manufacturing facility. These discrepancies can be caused by human error, theft, spoilage, damage, shrinkage, mislabeling, or inaccurate counting and have a negative impact on performance and efficiency. Wasting resources and increasing costs, disrupting production schedules and causing delays, reducing product quality and safety, lowering customer satisfaction and loyalty, and exposing the company to legal and regulatory risks are all potential consequences of inventory discrepancies in a food manufacturing process.
Should include the technical spare parts discrepancies which is stored in technical stores. In some big organization this can contribute almost a million due to wrong recording and misplacing
Another factor is yeild. Certain products may not yeild at the measured loss. Product issues are also affected by piece count and price per pound. In high volume facilities, its difficult to check every piece and frozen items after defrost may not weigh correctly. Fluid loss, cost of the ice on glazed fish and shrimp, etc
O controle de estoque serve para informar a quantidade disponível de cada item do estoque. Assim é possível controlar toda a movimenta??o de produtos e matérias primas: Quando você faz (direito) o controle de estoque, você ganha: Otimizando o seu investimento Levantando mais informa??es sobre suas vendas. Quando mais você souber sobre o seu negócio, melhor. Fazendo previs?o da demanda dos consumidores mais precisas Fazendo previs?es e estimativas de pedidos de fornecedores mais precisas
Inventory discrepancies pose significant challenges for food manufacturers, impacting various facets of the operation. These discrepancies, deviations between recorded and actual inventory levels, can stem from factors like inaccurate data entry, theft, or process inefficiencies. To measure them, employ regular cycle counts, reconciling physical stock with recorded levels. Implement robust inventory tracking systems utilizing technology like barcoding or RFID for accuracy. Embrace real-time monitoring to swiftly identify and rectify discrepancies, preventing cascading effects. Regularly analyze and report on these discrepancies, fostering a proactive approach to minimize their occurrence.
Para el control de inventarios durante el proceso, se debe balancear eficacia con eficiencia. Los controles sobre el inventario deben funcionar de la forma mas sencilla posible. Para esto deben existir en distintas etapas, identificando especialmente en aquellas en donde se "consumen" materiales. Un ERP robusto con uso de etiquetas RFID y puntos de control de materiales facilita esta tarea. En caso se encuentre discrepancias, estas deben ajustarse en el sistema de la manera mas pronta para tener información fiable que evite errores mayores y proceder a analisis de causa raíz de estas desviaciones. En almacenes, el control visual es una herramienta que junto con 5S, además de ERPs y tecnología para agilizar los conteos es básico y necesario.
Measuring inventory discrepancies is essential for identifying and correcting the root causes of the problem, as well as for improving inventory management and control. This process can help you track the performance and accuracy of your inventory system and processes, identify the sources and types of inventory errors and losses, evaluate the effectiveness of your inventory policies and procedures, implement corrective and preventive actions to reduce discrepancies, and monitor and report the results of your actions.
A melhor forma de fazer o seu controle de estoque é aquela que realmente funciona para você Ou seja, que atenda às necessidades da sua empresa, que resolva o seu problema e que caiba no seu bolso. Definir qual o melhor modelo de estoque para o seu negócio vai depender do porte da sua empresa, do que você oferece e do seu investimento.
it also has a cost perspective. Execess uses of a raw material would cost more for the end product. This can only be identified if inventory measurement is implemented.
Get your employees responsibible for inventory management out of their offices/desks and off their computers etc. often enough and long enough to go out into your facilities to experience reality and then learn how to deal with it.
Inventory should be taken by sections not by item or categories, that’s the mayor issue when doing inventory counts. Create spreadsheets identifying all sections for all groups of people doing physical counts
In manufacturing, measuring inventory discrepancies is like keeping your production machine well-oiled. Accurate inventory tracking ensures you've got the right materials at the right time. It's like knowing exactly how much gas is in your car before a long trip. Plus, it helps in spotting issues like waste and give away early on. Bottom line: Keeping a tight check on inventory is key to smooth operations and keeping your production lines humming without any nasty surprises.
One of the most common and simple ways to measure inventory discrepancies is to conduct periodic physical counts of your inventory and compare them with your inventory records. This can be done manually or with the help of barcode scanners, RFID tags, or other automated tools. The difference between the physical count and the record is the inventory discrepancy. You can calculate the inventory discrepancy rate as a percentage of the total inventory value or quantity. For example, if your physical count is 100 units and your record is 120 units, your inventory discrepancy rate is (120-100)/120 x 100% = 16.67%.
Research shows that the average inventory accurate rate is 65%, the closer you can get to that figure, the easier it will be to run your business efficiently. There are different ways to improve this: - Regular inventory audits -Organized inventory storage -Leverage technology -Limit access to inventory -Hire an inventory specialist -Unify inventory management systems
Registrar tudo (que chega e que sai, mercadorias e insumos): isso significa criar um cadastro para cada item – e atualizar conforme houver alguma mudan?a de status – contendo informa??es como código e descri??o, data de aquisi??o e de venda, além do pre?o pelo qual cada item foi vendido. Seja qual for o seus sistema (manual ou automático), fazer isso é OBRIGATóRIO.
My team does this daily: Instead of doing a full inventory count all at once, introduce cycle counting. This involves regularly counting a portion of your inventory. This can be more manageable and less disruptive. If there are discrepancies, you'll need to reconcile them. This might involve investigating causes like data entry errors, theft, or damage. (For this you will need Inventory SME's). Don't have any? you just found a gap. Keep an up-to-date accurate track record of all transactions. you will need this for your investigation. (You might find system errors as well)
Para hacer los inventarios, hay que sacar los datos del sistema y enfrentarlos con el conteo físico de los productos. Muy importante es respetar los lotes y caducidades para dar el stock exacto y, posteriormente, hacer una buena rotación de los productos
Tracking inventory discrepancies is an essential part of understanding when, where, how, and why they occur. This can help you identify patterns and trends of inventory errors and losses, as well as the factors and conditions that influence them. To track inventory discrepancies, you can use various tools and methods, such as inventory logs and reports - documents that record details of each inventory transaction - inventory tags and labels - identifiers that attach to each item or batch - inventory audits and reconciliations - processes that verify accuracy and completeness of records and counts - and inventory alerts and notifications - signals that warn of potential or actual problems.
Cheque seus registros: parece um detalhe besta, mas muitas empresas n?o fazem isso e acabam tendo problemas sérios quando descobrem que algo está errado com os valores. Uma dica é implementar algum sistema de “Inventário Rotativo”. Assim, o próprio sistema escolhe diariamente itens para checar e poderá detectar eventuais erros. Aten??o aos produtos perecíveis: se eles estragarem antes que você venda, você terá prejuízo. Por isso, n?o deixe de considerar esse detalhe quando planejar suas compras com fornecedores.
The most effective way to track and report inventory discrepancies is to implement a robust inventory management system that includes real-time tracking, regular audits, and reconciliation processes. Utilize barcoding or RFID technology for accurate data entry, conduct regular physical counts, and reconcile system records with physical inventory to identify and address discrepancies promptly. Regularly generate and review discrepancy reports to pinpoint issues and implement corrective actions.
Record every movement of the inventory. Like when is the inbound and outbound, where the inventory is placed, which shipment number. The best way is to implement RFID real-time tracking technology, but its costs maybe too expensive for SME.
Lo ideal es hacer semanalmente un control de los productos, de sus stocks, para llevar un seguimiento de los mismos. Mensualmente, revisión de los productos con fecha corta y revisar si los datos del sistema coinciden con los productos físicos
Reporting inventory discrepancies is a way to communicate the results and impacts of your inventory measurement and tracking to the relevant stakeholders. This can help inform and educate them about the current state and performance of your inventory, as well as the actions and improvements being taken or planned. You can use various formats and channels for reporting, such as inventory dashboards, summaries, analyses, meetings, and presentations. Such steps can help minimize and manage inventory discrepancies, improving accuracy and efficiency while enhancing food manufacturing performance and profitability.
Mapeie e integre sua opera??o: se você faz controle de estoque, também controla dados sobre as vendas do seu negócio. Com isso, você ganha sabendo com exatid?o quais s?o os produtos com maior e menor saída e com que frequência cada item tem que ser reposto. Descobrir isso é simples: basta analisar o histórico de vendas. A integra??o também possibilita uma maior sinergia com sua área de marketing e vendas para, por exemplo, realizar promo??es de queima de estoque quando tem muito produto parado, ou investir naquele produto que tem maior demanda.
Si semanalmente se hace ese control, se pueden comunicar esas desviaciones al equipo de trabajo. Estos controles ayudan a detectar entradas mal dadas, ya sea por cantidad o caducidad
Applying Lean manufacturing will support Inventory control and will reduce the inventory level to the optimum level. -Applying JIT (Just In Time) principle will control Inventory variance as inventory will be always at the minimum levels controlling the fluctuation in production planning and eliminating the sources of waste through value Stream will control and reduce the variance in inventories
Work on creating an Inventory SME team, these are your supervisors and leads that deal with transactions daily. They understand all operations and can easily identify gaps and errors in WIP and Raw material consumption better than anyone. Involve them as much as possible in inventory counts and rec process. This will develop their skills even more.
Estabele?a processos de controle de estoque: para evitar falhas, o melhor é definir rotinas claras de atualiza??o das ferramentas de controle. Por exemplo: toda vez que um produto for vendido, entrar imediatamente na planilha ou no sistema e atualizar o status do produto e o estoque disponível na loja. Envolva a equipe toda no processo: de que adianta investir em um sistema novo, se nem sua equipe (e muitas vezes nem você) saber?o usá-lo da forma correta?
A mí me ha resultado implementar el conteo cíclico y más en los productos de alto valor, y en los de clase A. Así siempre tenemos el control de cualquier movimiento irregular y mantener la administración del inventario, así como llevar el kpi actualizado y cumplir con las entregas a tiempo.