Redução de estoque em excesso ou obsoleto em uma indústria de injeção plástica, utilizando A3 e Business Intelligence

Abstract

Inventory management is essential for the continuity of industrial operations because it influences costs, material availability, physical space occupation, and the reliability of information used in decision-making. In a plastic injection molding company located in Manaus, chemical materials and other items were classified as excess or obsolete due to lack of movement, expiration, deterioration, linkage to discontinued projects, or lack of definition regarding reuse, disposal, or document regularization. Given this scenario, this research aimed to reduce excess or obsolete inventory through the joint application of the A3 methodology and Business Intelligence (BI). The research is characterized as applied, descriptive, and exploratory, with a qualitative and quantitative approach. Data extracted from SAP, physical inventory, movement records, internal documents, the A3 report, and BI dashboards were used. The A3 methodology made it possible to structure the problem, identify causes, and define countermeasures, responsible parties, deadlines, and monitoring indicators, whereas BI enabled data integration and the presentation of information on inventory, movements, repair shipments, and external returns in visual dashboards. As a result, the balance of chemical materials was eliminated in June, and the overall warehouse inventory was reduced from BRL 1,597,238.00 to BRL 526,266.00, equivalent to 67.05%.