How would you optimize inventory storage to minimize waste in your manufacturing operations?

1. *Inventory Classification*: Categorize inventory into fast-moving, slow-moving, and dead stock. Prioritize storage for high-demand items. 2. *Storage Layout Optimization*: Design a logical and efficient storage layout to reduce travel time and improve accessibility. 3. *software implemented 4. *First-In-First-Out (FIFO)*: 5. *Storage Capacity Optimization*: Maximize vertical storage space and consider compact storage solutions. 6. *Inventory Reduction*: Implement just-in-time (JIT) delivery, reduce batch sizes, and negotiate with suppliers to minimize inventory levels. 7. *Warehouse Organization*: Label and sign storage areas, use clear labeling, and maintain a clean and organized warehouse. 8. Regular audit

In addition to frequency of usage, other criteria to make groups are homogeneity of the products such that they occupy less space while ensuring maximum efficiency in other warehouse activities such as picking and counting.

Just manage the Cycle Requirements Consumption Movement Design your own policies that utilizes less efforts keep things simple

To avoid spending time for searching items we should create replenishment tasks to maximizing level of the pickfaces during a specific time, usually off-peak hours.

Optimizing inventory storage to minimize waste involves several key strategies. Implement a Just-In-Time (JIT) inventory system to reduce excess stock. Use data analytics to forecast demand accurately, ensuring you order only what's needed. Organize storage using the First-In, First-Out (FIFO) method to prevent items from becoming obsolete. Regularly audit inventory to identify slow-moving or surplus items and adjust purchasing accordingly. Utilize vertical storage solutions to maximize space and improve accessibility. Employ inventory management software for real-time tracking and automated reordering. These measures help reduce waste, improve efficiency, and lower costs.

Consider to get more crucial parameters like maturity time or expiry dates, consider to measure not on FIFO but on FEFO (first expires first out). monitor actively semifinished goods which are CLOSE to but not expired yet. Have real time overviews with drill down option in your IT reports as you can manage your future still. Don't focus on what has already been expired. Have a clear batch or lot based storage-in and storage-out strategy.

Implementing a FIFO system is crucial for minimizing waste and maintaining product quality in manufacturing. To train unfamiliar employees, start with a clear explanation of the FIFO concept and its benefits. Use visual aids and real-life examples to illustrate how it works. Conduct hands-on training sessions where employees practice organizing and retrieving inventory based on the FIFO method. Implement labeling and signage to guide correct item placement. Provide ongoing support and refresher courses to reinforce the practice. Regularly monitor and give feedback to ensure adherence. This comprehensive training ensures employees understand and effectively implement FIFO, enhancing inventory management.

That's interesting and also needs to be considered. If we think it through we have to take the whole process into account. Why not start where expiring goods enter the system? So if you can, don't use them, if you don't, let goods that expire be delivered in the smallest batches possible and as continuously as possible, too.

O método FIFO (First-In, First-Out) é crucial para gerenciar estoques de maneira eficaz, garantindo que os itens mais antigos sejam usados primeiro. Isso previne obsolescência e deterioração, mantendo os produtos frescos, especialmente importante em indústrias como a alimentícia e farmacêutica. Embora simples e eficaz, o FIFO requer uma organização cuidadosa do espaço de armazenamento e monitoramento constante para assegurar que os itens mais antigos sejam utilizados antes. A sua implementação bem-sucedida pode melhorar a rastreabilidade e reduzir desperdícios, mas depende de uma execução disciplinada e uma infraestrutura adequada.

Well, in the age of AI, use all available data to get the best forecasts possible to prepare. Still even better is not having to forecast but smoothing out of continuous demand and setting up pull systems that self-optimize for efficiency and effectiveness. Think hard about what you can do to create continuous demand.

A previsão de demanda é crucial para evitar o excesso de estoque, alinhando compras e produção com a demanda real dos clientes. Ela permite planejar a quantidade exata de produtos necessários, reduzindo custos de armazenamento e o risco de obsolescência. Isso melhora o fluxo de caixa, liberando capital para outros investimentos, e aprimora a eficiência operacional ao permitir uma programação de produção mais precisa. Além disso, garante maior satisfação do cliente ao evitar rupturas de estoque. Em resumo, a previsão de demanda é essencial para gerenciar estoques de maneira eficiente, reduzindo custos e atendendo melhor às necessidades do mercado.

Realizar auditorias regulares no estoque de uma empresa é crucial para garantir a precisão dos registros, prevenir fraudes, otimizar o uso de recursos, cumprir normas regulatórias, melhorar a eficiência operacional e promover transparência financeira.

A melhoria da eficiência na utilização do espaço com o uso do 5S é crucial para organizar de forma sistemática e otimizar os ambientes de trabalho. Este método promove a eliminação do desnecessário, organização eficiente dos itens, limpeza constante, padronização de processos e disciplina para manter essas práticas. Implementar o 5S reduz desperdícios de espaço, melhora o acesso aos materiais, aumenta a produtividade e promove um ambiente de trabalho mais seguro e organizado, beneficiando tanto os colaboradores quanto a eficiência operacional da empresa.

Deploying the right storage mode as per product needs is equally important as FIFO / FEFO or Products grouping/ segregation or demand forecasting.

Utilizing space is great, maximizing can lead to long time for accessing stored items. That can be harmful as well. So please keep 4 dimensions in mind. - length of you storage area - width of your storage area -height, "don't just store 🏬 on the floor"™, aka 3D - time ⌚, make it easy to recover stored items when you need them, think about that situation, as well as po at the point in time when you are storing it, shelving it.

Adopting a culture of continuous improvement ensures that inventory storage optimization efforts remain ongoing and effective. Encourage employees to regularly assess and suggest enhancements to storage practices. Implement Kaizen events and Lean methodologies to identify inefficiencies and develop solutions collaboratively. Use data analytics to monitor inventory performance and adjust strategies in real time. Provide ongoing training to keep staff updated on best practices. Celebrate successes and learn from setbacks to foster a proactive mindset. This dynamic approach keeps inventory management efficient, reducing waste and adapting to changing demands.

Continuous improvement is only continuous if it is done by every employee every day on everything that's being done. SAFe as lean and agile framework for building business agility mentions relentless improvement. Mike Rother explains it well, too, in Toyota Kata. Coach all employees to build this part of consciousness into habits.

I consider all what have said above when using big data concept by linking the ERP system of the company with other department modules ,means quality , maintenance, warehouse, planing and procurement. New technologies such ,robots, cameras and smart labels will facilitate this new approach.

I Think we need to conduct a training program for everyone and make them realise the importance of Storage/Space Utilisation in any manufacturing unit.