Enhancing inventory accuracy in dairy industries
Goal: The goal is to analyze the application of Lean Six Sigma and DMAIC in the inventory management of a dairy industry, aiming to optimize inventory accuracy, reduce picking errors, and enhance OTIF performance, thereby improving overall operational efficiency. Design / Methodology / Approach:...
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| Format: | Article |
| Language: | English |
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Associação Brasileira de Engenharia de Produção (ABEPRO)
2025-07-01
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| Series: | Brazilian Journal of Operations & Production Management |
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| Online Access: | https://bjopm.org.br/bjopm/article/view/2439 |
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| author | Francisco Tiago Araújo Barbosa Maria Silene Alexandre Leite Mauro Sergio Carneiro Mascarenhas Rogerio Santana Peruchi |
| author_facet | Francisco Tiago Araújo Barbosa Maria Silene Alexandre Leite Mauro Sergio Carneiro Mascarenhas Rogerio Santana Peruchi |
| author_sort | Francisco Tiago Araújo Barbosa |
| collection | DOAJ |
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Goal: The goal is to analyze the application of Lean Six Sigma and DMAIC in the inventory management of a dairy industry, aiming to optimize inventory accuracy, reduce picking errors, and enhance OTIF performance, thereby improving overall operational efficiency.
Design / Methodology / Approach: This applied and descriptive research adopts an action research strategy, with researchers actively participating in the project's execution. Lean Six Sigma principles and the DMAIC framework were systematically applied to inventory, picking, and supply processes. Statistical validation was conducted using the Z-test for two proportions to confirm the effectiveness of the improvements implemented.
Limitations of the investigation: The study focuses on a case analysis in a dairy processing environment; however, the structured methodology adopted allows replication in industries characterized by operational complexity, perishability, or high inventory turnover.
Practical implications: The study offers valuable insights for logistics, procurement, and operations professionals. The implemented methodologies led to a 36.63% reduction in inventory discrepancies, resulting in cost savings of R$124,540.56. Additionally, significant improvements were achieved in controlling picking errors and enhancing OTIF performance, underscoring the critical role of structured continuous improvement methodologies in inventory management.
Originality / Value: This research addresses a gap in applied studies on inventory management in the dairy sector, demonstrating the successful application of Lean Six Sigma and DMAIC to achieve substantial operational improvements. The study presents a replicable model for other industries seeking to optimize inventory control, minimize operational errors, and elevate supply chain performance.
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| format | Article |
| id | doaj-art-cbd9a0e4136740d3ab31e894e6bc23a3 |
| institution | Kabale University |
| issn | 2237-8960 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Associação Brasileira de Engenharia de Produção (ABEPRO) |
| record_format | Article |
| series | Brazilian Journal of Operations & Production Management |
| spelling | doaj-art-cbd9a0e4136740d3ab31e894e6bc23a32025-08-20T03:27:37ZengAssociação Brasileira de Engenharia de Produção (ABEPRO)Brazilian Journal of Operations & Production Management2237-89602025-07-0122210.14488/BJOPM.2439.2025Enhancing inventory accuracy in dairy industriesFrancisco Tiago Araújo Barbosa0Maria Silene Alexandre Leite1Mauro Sergio Carneiro Mascarenhas2Rogerio Santana Peruchi3Federal University of Paraíba (UFPB), João Pessoa, PB, Brazil.Federal University of Paraíba (UFPB), João Pessoa, PB, Brazil.Federal University of Paraíba (UFPB), João Pessoa, PB, Brazil.Federal University of Paraíba (UFPB), João Pessoa, PB, Brazil. Goal: The goal is to analyze the application of Lean Six Sigma and DMAIC in the inventory management of a dairy industry, aiming to optimize inventory accuracy, reduce picking errors, and enhance OTIF performance, thereby improving overall operational efficiency. Design / Methodology / Approach: This applied and descriptive research adopts an action research strategy, with researchers actively participating in the project's execution. Lean Six Sigma principles and the DMAIC framework were systematically applied to inventory, picking, and supply processes. Statistical validation was conducted using the Z-test for two proportions to confirm the effectiveness of the improvements implemented. Limitations of the investigation: The study focuses on a case analysis in a dairy processing environment; however, the structured methodology adopted allows replication in industries characterized by operational complexity, perishability, or high inventory turnover. Practical implications: The study offers valuable insights for logistics, procurement, and operations professionals. The implemented methodologies led to a 36.63% reduction in inventory discrepancies, resulting in cost savings of R$124,540.56. Additionally, significant improvements were achieved in controlling picking errors and enhancing OTIF performance, underscoring the critical role of structured continuous improvement methodologies in inventory management. Originality / Value: This research addresses a gap in applied studies on inventory management in the dairy sector, demonstrating the successful application of Lean Six Sigma and DMAIC to achieve substantial operational improvements. The study presents a replicable model for other industries seeking to optimize inventory control, minimize operational errors, and elevate supply chain performance. https://bjopm.org.br/bjopm/article/view/2439DMAIC Quality toolsInventory management OTIF (On Time In Full) |
| spellingShingle | Francisco Tiago Araújo Barbosa Maria Silene Alexandre Leite Mauro Sergio Carneiro Mascarenhas Rogerio Santana Peruchi Enhancing inventory accuracy in dairy industries Brazilian Journal of Operations & Production Management DMAIC Quality tools Inventory management OTIF (On Time In Full) |
| title | Enhancing inventory accuracy in dairy industries |
| title_full | Enhancing inventory accuracy in dairy industries |
| title_fullStr | Enhancing inventory accuracy in dairy industries |
| title_full_unstemmed | Enhancing inventory accuracy in dairy industries |
| title_short | Enhancing inventory accuracy in dairy industries |
| title_sort | enhancing inventory accuracy in dairy industries |
| topic | DMAIC Quality tools Inventory management OTIF (On Time In Full) |
| url | https://bjopm.org.br/bjopm/article/view/2439 |
| work_keys_str_mv | AT franciscotiagoaraujobarbosa enhancinginventoryaccuracyindairyindustries AT mariasilenealexandreleite enhancinginventoryaccuracyindairyindustries AT maurosergiocarneiromascarenhas enhancinginventoryaccuracyindairyindustries AT rogeriosantanaperuchi enhancinginventoryaccuracyindairyindustries |