Integrating Lean Warehousing and DDMRP to Improve Inventory Flow Efficiency in a Peruvian Commercial SME Warehouse

Damian-Rojas R.G.; Pascual-Mendoza M.L.; Taquía-Gutierrez J.A.; Quiroz-Flores J.C. · SSRG International Journal of Mechanical Engineering (2025) · DOI: 10.14445/23488360/ijme-v12i12p106

Resumen

Like many other industries, the conveyor lift belt distribution market encounters many issues related to inventory, including issues such as inventory control, restocking, and warehouse organization. Most of the pertinent literature, including the ones on Lean Warehousing and DDMRP, focuses on them separately. Quite a number of scholars have tried to cross-integrate these two approaches, though in the context of Lean Warehousing and DDMRP pertaining to commercial Small and Medium Enterprises. This research gap on the integration of DDMRP and Lean Warehousing has been addressed by proposing a 5S DDMRP model whereby DDMRP streamlines inventory conditioning and reliability in addition to the optimization of inventory. The model developed from this research attempts to bridge the gap in the model’s effectiveness in meeting demand and usefulness in aligning warehouse operations with demand-driven logic. Evidence from analyses of DDMRP implementation shows stockouts declined by 11.62%, inventory accuracy increased by 61.20%, and an overall 32% cost reduction. This research sheds light on the inventory flow of DDMRP in terms of reliability and efficiency. The 5S DDMRP model aims to assist Small and Medium Enterprises by providing a practical solution that does not involve overly sophisticated warehouse automation. On the other hand, practitioners and analysts are encouraged to focus on expanding the integration of automation, which has been proven to enhance investment adaptability alongside the investment needed to enhance it. This particular attribute will enhance the system’s responsiveness and multi-capability to variable demand integration in real time.

Instituciones: Universidad de Lima