Gestão de estoque em tempos de crise

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Algumas empresas continuam a produzir no mesmo ritmo, mas fazem parte de uma minoria.

Nós, da maioria que foi seriamente afetada, precisamos mais do que nunca cortar os nossos custos. Para sobrevivermos a este momento e termos condições de reagir no momento da retomada. Ninguém sabe exatamente quando isso vai ocorrer, mas uma coisa é certa, ela vai acontecer.

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Algumas empresas cortaram salários, deixaram de pagar os seus impostos, seus aluguéis, etc. Tudo isso teve que ser revisto, sem dúvida nenhuma. Foram cortes de custo excepcionais, feitos exclusivamente neste momento de crise. Porém existe um custo que pode e deve ser cortado definitivamente. É um custo que a sua empresa carrega sem avaliar muito bem, e que para a sua competitividade deve ser cortado, e permanecer assim após a retomada. Estou falando do custo de estoques.

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Estoque em processo e na forma de produto acabado, significam dinheiro estocado na forma de matérias primas, componentes e mão de obra. Existe muita mão de obra estocada em seu galpão. Existe muita matéria prima. Existe muito trabalho estocado.

A maior parte das empresas têm estoques desbalanceados, ou seja, têm estoques em excesso em alguns itens e faltam outros itens. É o famoso “falta e sobra”. Isso pode acontecer devido a uma série de fatores ocasionais, tais como demandas inesperadas, equipamentos indisponíveis, falta de matérias primas ou problemas de qualidade.

Mas um motivo dos mais comuns, que não é ocasional, é a política de reposição desses estoques. Critérios obsoletos na definição de tamanho de lotes, como o cálculo do “lote econômico”, ou a utilização de um MRP gerando ordens baseadas em previsões, não ajudam nem um pouco neste balanceamento.

Neste cenário, a tendência de excessos de estoque é predominante, pois quem produz busca segurança e produz a mais. Isso significa que existe muito mais dinheiro do que o necessário, estocado em seu inventário.

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Estoque balanceado significa que, se convertermos os volumes dos estoques em tempo necessário para consumi-los, item a item, os tempos estocados deveriam ser bastante próximos.

Se tivermos um item com quantidade suficiente para 3 meses e outro item com quantidade para 2 dias, temos um desbalanceamento no estoque.

Essa visão dos estoques convertidos em tempos de consumo foi, sem dúvida, uma das maiores contribuições operacionais do pensamento enxuto.

Tudo é calculado em tempo. É preciso calcular o tamanho do lote, e consequentemente do estoque, em termos de tempo de consumo.

Alguns itens são consumidos todos os dias, em grandes quantidades. Outros, raramente são consumidos. Como tratá-los por igual?

Pode ser que uma semana de estoques para o item bestseller seja uma quantidade muito grande, e pode ser que o lote de uma semana para o item pouco consumido seja expresso em uma fração.

Aí, mais uma vez, entra o velho e bom Paretto para nos ajudar. Podemos classificar os itens de acordo com a sua demanda.

Os itens pouco consumidos, os classe C no Paretto de demanda, poderiam ser feitos para um tempo de consumo maior, digamos por exemplo, 20 dias de consumo. Ainda assim, considerando a sua demanda menor, geraria relativamente pouco valor financeiro atrelado ao estoque.

O oposto ocorre com os itens de alta demanda, os classe A. Dado o grande volume de demanda, se gerarmos lotes para os mesmos 20 dias, poderíamos gerar um custo muito alto de estoque, o que seria oneroso.

Talvez neste caso o tamanho “bom” de reposição seja apenas 3 dias. Isso significaria lotes que duram 3 dias, que serão produzidos também com esta frequência.

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Nossos clientes conseguem reduzir seus estoques de 20% a 70% com o Kanban Eletrônico

E usufruir dos benefícios gerados, tais como:

[/fusion_text][fusion_checklist hide_on_mobile=”small-visibility,medium-visibility,large-visibility” circlecolor=”#05b511″ class=”checklist-black”][fusion_li_item icon=””]Aumento considerável do giro de estoques[/fusion_li_item][fusion_li_item icon=””]Redução do capital de giro[/fusion_li_item][fusion_li_item icon=””]

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Essa subdivisão dos itens por demanda pode ser feita em quantas categorias se quiser. Mas, supondo a subdivisão clássica do Paretto, os itens poderiam ser divididos em classes A, B e C.

O cálculo da quantidade de itens em cada categoria não é tão simples, e envolve a capacidade de produção e os tempos de setup envolvidos. Mas para efeito de ilustração aqui, poderiam ser: itens A com 3 dias de estoque, itens B com 9 dias e itens C com 20 dias, por exemplo.

Com isso, dentro de cada uma destas classes, deve-se manter o estoque balanceado.

Não foram raras reduções de estoques em 50%, sem afetar a qualidade de entrega desses estoques.

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O processamento de informações para fazer isso pode envolver uma massa de dados muito grande, dependendo da variedade de itens em estoque.

Aqui na Hominiss, nós desenvolvemos uma ferramenta para fazer esse processamento de informações de estoques, chamada Dimensionamento de Kanban, ou DK, que viabiliza esse balanceamento em muito pouco tempo e, trabalhando integrada com o nosso Kanban Eletrônico, melhora muito a eficácia operacional.

Analise os seus estoques. Pode ter muito mais dinheiro armazenado lá do que o necessário. E este dinheiro pode ser ainda mais útil nesta época difícil por que passamos.

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Antônio Rentes é Doutor em Engenharia de Produção pela USP e PhD pela Virginia Tech. Especialista em Gestão de Mudanças (Change Management) e Melhoria de Processos, trabalha há 17 anos como consultor em gestão da mudança e melhoria de processos de empresas de diversos segmentos e é professor sênior da Escolha de Engenharia de São Carlos – USP. Sócio diretor da Hominiss Solutions.

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