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Batch Manufacturing Inventory Warehouse

How to Improve Inventory Accuracy

For co-packers and private label manufacturers, inventory management and batch tracking are not just operational tasks; they are pivotal to maintaining quality, efficiency, and customer satisfaction. These processes are the backbone of production, ensuring that the right products are available at the right time, in the right quantities. For these manufacturers, inventory accuracy is not a mere metric; it’s a vital sign of business health.

What is an Inventory Audit?

An inventory audit is a comprehensive examination of a company’s inventory assets. This process goes beyond mere counting; it delves into the accuracy of inventory records, evaluates the condition and quality of the stock, and assesses how well inventory is managed. For manufacturers, particularly in specialized industries like cosmetics, this is critical. A successful audit ensures that the recorded inventory matches the physical stock, a key factor in maintaining product quality and customer trust.

Cosmetic manufacturer SDB is able to quickly perform a full inventory of their two warehouses across 80,000 square feet. They can do that because all of their inventory is barcoded and tracked by location. Mar-Kov’s cycle count feature. Mar-Kov tells users exactly what should be in each location and a quick barcode scan can verify the information. 

Audit Procedures for Inventory

Effective audit procedures for inventory are methodical and tailored to the specific needs of the industry and company. These procedures typically start with planning and preparation, where auditors understand the company’s inventory systems and set objectives for the audit. The next step usually involves physical inventory counts, which are often cross-checked against the company’s records for accuracy.

In the context of manufacturing, especially in sectors like cosmetics, these procedures might also include analyzing batch records, verifying the condition and quality of the inventory, and assessing the efficiency of inventory management systems. Advanced systems like those offered by Mar-Kov can significantly streamline this process, integrating seamlessly with the existing workflows of a manufacturer. By automating data collection and analysis, these systems not only facilitate a more accurate inventory count but also provide valuable insights for improving overall inventory management.

Buffer Inventory vs. Safety Stock

In the world of inventory management, the terms ‘Buffer Inventory’ and ‘Safety Stock’ are often used interchangeably, yet they serve distinct purposes. Understanding the nuance between these two is helpful manufacturer aiming to optimize their inventory strategy.

Buffer Inventory

Buffer inventory, also known as buffer stock, is a supply of goods or materials kept on hand to protect against fluctuations on the demand side. Essentially, it acts as a safeguard to ensure that a company can continue to operate and meet customer demands if there is increased buying interest. This strategic stock helps in maintaining customer satisfaction and business continuity.

Safety Inventory

Safety Inventory, also known as Safety Stock, is the additional quantity of an item kept in the inventory to protect on fluctuations of the supply side.This is designed to protect against issues like delays in supply chain. Safety stock acts as a protective buffer, ensuring that operations continue smoothly even when unexpected disruptions occur.

How to Calculate Safety and Buffer Inventory

Both Safety and Buffer Inventory are there to keep a batch manufacturer moving when inventory stress moves outside of the forecast. Calculating the right amount of safety inventory is a delicate balance. Too little may lead to stockouts, while too much can tie up valuable resources. The calculation typically involves understanding demand and supply variability. A basic formula for calculating safety inventory is:

Safety Inventory=(Maximum Daily Usage×Maximum Lead Time)−(Average Daily Usage×Average Lead Time)

If you typically use 100 Units a day and the lead time is a week, then you will go through 700 units a week. If delays could turn the lead time to two weeks, we need some buffer inventory. If increased demand could increase daily usage to 200 units per day we need more inventory. Plugging the numbers into the equation above gives us

Safety Inventory = (200×14)-(100×7) = 2100 Units. 

This formula considers the worst-case scenario in both usage increase and supply delay, ensuring that the business is prepared for unexpected fluctuations.

How to Avoid Overstocking Inventory

Overstocking inventory can be just as detrimental as understocking. Excess inventory ties up capital, increases storage costs, and can lead to waste, especially in industries with products that have limited shelf lives, like food and cosmetics. 

To avoid overstocking, manufacturers must employ effective inventory management strategies. These include:

  1. Accurate Demand Forecasting: Utilizing advanced analytics and historical data to predict customer demand more accurately.
  2. Accurate Inventory: By using barcoding and MES software companies can be confident their inventory is accurate in real time. 
  3. Just-In-Time Inventory: Adopting a JIT approach, where materials are ordered and received as needed, reducing the need for large inventory holdings.
  4. Leveraging Technology: Implementing inventory management systems like Mar-Kov, which provide real-time data and analytics to optimize inventory levels.

By adopting these strategies, manufacturers can maintain an optimal inventory level, ensuring they have enough stock to meet demand without overextending their resources.

Reaching Inventory Accuracy Goals

Achieving high inventory accuracy is not just a target; it’s a journey that involves continuous improvement and integration of effective strategies. This journey is critical for manufacturers, as it directly impacts customer satisfaction, reduces waste, and improves financial performance.

Mar-Kov’s batch manufacturing software play a pivotal role in this journey. These solutions bring together essential elements of a modern manufacturing system, encompassing inventory management, safety stock control, audit procedures, and more. By integrating these diverse elements, Mar-Kov offers an intuitive and user-friendly system that simplifies complex inventory management challenges.

Integrating Mar-Kov Solutions for Enhanced Inventory Management

Mar-Kov’s solutions are designed to address the unique needs of batch manufacturers. These solutions provide:

  1. Real-Time Inventory Tracking: Offering up-to-the-minute data on inventory levels, helping manufacturers make informed decisions quickly.
  2. Advanced Forecasting Tools: Utilizing predictive analytics to anticipate demand, thereby aiding in maintaining optimal inventory levels.
  3. Automated Audit Procedures: Streamlining the inventory audit process, ensuring accuracy and compliance with regulatory standards.
  4. Customizable Reporting: Allowing manufacturers to create tailored reports that track key inventory metrics, aligning with their specific goals.

By implementing Mar-Kov’s solutions, manufacturers can not only achieve their inventory accuracy goals but also enhance overall operational efficiency. These solutions help in minimizing overstocking and stockouts, optimizing safety stock levels, and ensuring a smoother audit process.

Making the Right MES Choice

When deciding on a Manufacturing Execution System (MES), it’s crucial to consider how well it aligns with your inventory management needs. Mar-Kov’s solutions stand out for their focus on the specific challenges faced by batch manufacturers. The system’s ease of use, coupled with its comprehensive suite of tools, makes it an ideal choice for those looking to streamline their inventory processes and achieve greater accuracy.

For more information on how Mar-Kov can transform your manufacturing operation, explore our case studies and blog posts for real-world examples of how our solutions have benefited others in your industry.

Connect with Us

Interested in learning more about how Mar-Kov can help you reach your inventory accuracy goals? Contact us today to discuss your needs and discover how our solutions can be tailored to your business. Let us help you take the next step towards efficient and accurate inventory management.