Given that cost, quality, and delays are the key performance indicators (KPIs) for manufacturing companies, finding solutions to reduce costs and eliminate non-value-added activities is essential. Industry 4.0 tools, particularly RFID scanning, are increasingly recommended to meet these demands. This paper explores the positive impact of RFID technology on Work-in-Progress (WIP) stock management in an automotive manufacturing company. WIP stock discrepancies can lead to costly issues, such as production line stoppages, excess or obsolete stock, and increased costs due to premium freight or inventory adjustments. These discrepancies occur because procurement relies on system stock data for raw material orders using the MRP method, making it crucial for physical stock to match system records with minimal variance. The methodology for addressing this issue includes a literature review to explore existing solutions, followed by selecting RFID scanning as the optimal method based on a multi-criteria analysis. A feasibility study was conducted, and a pilot line was chosen for real-world testing. The solution involves installing RFID gates at key points: the reception area to confirm incoming stock, the supermarket for stock movement control, and production stations to track empty boxes. These measures ensure real-time stock updates, minimizing discrepancies and optimizing WIP stock management.

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Optimizing WIP Stock Management Through Industry 4.0 Tools: A Manufacturing Case Study

  • Taraa Chaymae,
  • Ezzine Latifa,
  • El Moussami Haj

摘要

Given that cost, quality, and delays are the key performance indicators (KPIs) for manufacturing companies, finding solutions to reduce costs and eliminate non-value-added activities is essential. Industry 4.0 tools, particularly RFID scanning, are increasingly recommended to meet these demands. This paper explores the positive impact of RFID technology on Work-in-Progress (WIP) stock management in an automotive manufacturing company. WIP stock discrepancies can lead to costly issues, such as production line stoppages, excess or obsolete stock, and increased costs due to premium freight or inventory adjustments. These discrepancies occur because procurement relies on system stock data for raw material orders using the MRP method, making it crucial for physical stock to match system records with minimal variance. The methodology for addressing this issue includes a literature review to explore existing solutions, followed by selecting RFID scanning as the optimal method based on a multi-criteria analysis. A feasibility study was conducted, and a pilot line was chosen for real-world testing. The solution involves installing RFID gates at key points: the reception area to confirm incoming stock, the supermarket for stock movement control, and production stations to track empty boxes. These measures ensure real-time stock updates, minimizing discrepancies and optimizing WIP stock management.