Challenge
The organization faced severe inventory and production inefficiencies across multiple departments. Parts were scattered throughout the facility, identified by handwritten marker labels, taped notes, or loose paperwork. Manufacturing utilization was low, production was bottlenecked, and schedules were consistently missed. Internal systems and ERP reports showed massive discrepancies—inventory values were off by millions—making planning, forecasting, and decision-making unreliable.

Solution
I led a full reorganization of each department, redesigning inventory storage and identification from the ground up. All parts were numerically organized and clearly labeled using a magnetic labeling system attached to warehouse shelving, allowing layouts to be easily adjusted as inventory levels changed. This created a logical, repeatable structure that aligned the physical floor with ERP data. I also implemented cycle counting for high-value and frequently used parts to maintain ongoing accuracy and control.

Outcome
The new system dramatically improved part visibility, production flow, and inventory accuracy. Manufacturing delays were reduced, utilization improved, and teams could quickly locate materials without disruption. At year-end, a full physical inventory count showed discrepancies of only $30,000, down from variances in the millions—restoring confidence in reporting, scheduling, and operational planning.