Need to put a system in place for precise reporting of incoming materials, issuance of materials and reporting consumption in ERP system. Use of mass flow meters for fluids, gravimetric weighing systems for solids, online weight checkers helps to track consumption accurately and hence prevents inventory mismatch. In addition, there should be a process of monthly stock reconciliation to manage surprises.

Implementaria sistemas automatizados de rastreamento, como RFID ou IoT, e realizaria auditorias regulares para identificar e corrigir discrepâncias rapidamente

✅ Implementar sistemas de monitoreo en tiempo real: Utilizar tecnología avanzada para rastrear el inventario con precisión y evitar errores manuales. ✅ Optimizar el control de calidad: Aplicar procesos rigurosos para detectar inconsistencias y corregirlas antes de que afecten la producción. ✅ Automatizar la gestión de inventario: Incorporar software especializado que reduzca la intervención humana y mejore la exactitud. ✅ Capacitar al equipo en mejores prácticas: Asegurar que todos los empleados comprendan los procedimientos de control y seguimiento. ✅ Realizar auditorías periódicas: Evaluar el inventario de manera regular para identificar y corregir posibles desviaciones.

You need to control the material chain from inbound to manufacturing and outbound WH. Every material movement needs to be recorded. -Incoming material receiving -Moving to WH -Moving from WH to production line / production WH (if existing) -Assembled materials -Scrapped materials / Disassembled materials -Return to WH materials (Main / Production WH) This can be enabled with Intra-Plant logistics SW + MES. IPL SW taking care of every material movement inside the plant and MES taking care of the consumption in production (+scrap). Of course tracking of materials means that you have Unique identifiers on each material (batch or S/N) those are attached during the receiving. Best systems forces all these steps reducing human errors.

. Incoming material. .consumption . . Work in process . . Losses missed out. . Frequent audit. . Material reconciliation. . Unit of measurement uniformity. Units vs kgs with tolerance. All the above would help in reconciliation .

Establish clear inventory accountability with the inventory team. The team must ensure that stored inventory is regularly audited through cycle counts. The team must be effective at controlling the incoming and outgoing inventory by ensuring that inventory is counted or checked coming into the stockroom or going out of the stockroom.

The solution involves two key phases: 1. Optimizing IT Systems: Establishing a robust and adaptable IT infrastructure designed for the manufacturing industry. This system will support seamless modifications and upgrades, aligning with business needs and technological advancements. 2. Effective Reporting Tools: Implementing appropriate tools to ensure actionable and efficient reporting. These tools will empower decision-makers across hierarchies with relevant, real-time insights. Additionally, a streamlined workflow for notifications and approvals will be set up. This ensures that proper checks are in place at critical points, enhancing accountability and operational efficiency.

To address discrepancies in inventory, follow these steps: 1. Identify the root cause of the discrepancies and take initial corrective action by conducting a complete stock count (100%). 2. Classify the percentage of discrepancies for each item and recalibrate them accordingly. Keep in mind that adjustments should be considered as a last resort. For preventive measures, establish a procedure to maintain inventory accuracy by: 1. Categorizing items by type of inventory, their strategic importance (using the ABC classification), and demand fluctuations (using the XYZ classification). 2. Conducting regular cycle counts based on the categorized items. 3. Performing a complete stock opname at least once a month.

Standardize Counting Procedures: Use consistent methods for physical counts, including timing, personnel, and documentation. Implement Cycle Counting: Regularly count small inventory segments rather than relying solely on annual full counts to catch errors early. Leverage Technology: Adopt barcode scanners or RFID systems to reduce human error and streamline tracking. Train Your Team: Ensure all staff understand inventory processes and the importance of accuracy. Reconcile Discrepancies Promptly: Investigate and resolve any mismatches immediately to prevent ongoing issues. Integrate Systems: Align your inventory management software with production and procurement systems for real-time data accuracy.