Predicting the proper amount of inventory that is required for your production is a hard task there is no doubt about that. There are other methods of scheduling your inventory that you may not even be aware of. How about integrating your current inventory system with a scheduling system also?

The way it would work is actually quite simple. Say you have 500 parts in your inventory, as each part is individually taken out it can either be represented by a card or scanned to notify that it has left the inventory room. Once the system has registered a certain amount of parts as removed (we’ll just say 250 for this explanation) the inventory system will alert the scheduling system. The scheduling system will automatically alert those that are responsible that the inventory is low and needs to be replenished. Some scheduling systems can even electronically order the required stock without the hassle of alerting staff members. This is similar to a Kan Ban system where inventory is managed by a card system to keep the proper stock replenished.

The benefits to implementing a system such as this include the opportunity to become leaner and save time and money. Instead of requiring management to walk the floor choosing which items need replenished the electronic ordering system will eliminate those wasted hours. The scheduling system can be changed throughout the year depending on when demand is high, possibly in the summertime and when it is reduced.

Here is a web page that talks more about scheduling systems and the opportunities they offer. Surf through some of the articles that are available I think you might find them to be beneficial.