Logistics Model To Reduce Inventory Discrepancies By Applying Digital POKA-YOKE, RFID And WMS In The Warehouses of White-Goods Company

Irigoin-Sánchez C.A.; Mascaro-Levano D.V.; Corzo-Chavez J.A.; Viacava-Campos G. · Proceedings of the Conference on Production Systems and Logistics (2026) · DOI: 10.15488/20990

Resumen

Inventory accuracy is a key element for maintaining reliable and efficient logistics operations. In this context, this study analyzes record accuracy and proposes innovative digital solutions. This study addresses the problem of inventory record accuracy (IRA) in white-goods warehouses, where a huge discrepancy was detected between the physical inventory and the system records, resulting in an accuracy level of 89%, below the industry benchmark of 98%. This situation generates annual economic losses of USD 129,888, rework, and low reliability in logistics decision-making. An integrated improvement model is proposed, based on three tools: Pick-to-Light, aimed at reducing picking errors through visual guidance; RFID with overload alerts, designed for real-time physical validation and traceability; and a digital Poka-Yoke, implemented to automatically block incorrect or incomplete records. The study demonstrates that the integration of digital control and traceability tools represents an innovation applicable to logistics management, combining Lean technologies with intelligent validation systems to address inventory accuracy from a preventive and automated perspective. This approach goes beyond traditional physical audits, proposing a layered control model that ensures real-time coherence between physical and digital inventory. Its modular and adaptable structure allows the proposal to be replicated in other industrial sectors or logistics contexts, where traceability and inventory accuracy are critical factors for supply chain efficiency. Overall, the study contributes a validated and replicable methodological framework that advances knowledge in digital logistics management and continuous improvement. Validation was carried out through computational simulation, comparing the current and improved scenarios, revealing an increase in inventory accuracy from 89% to 98%, a significant decrease in picking, dispatch, and operational errors, and annual savings exceeding USD 75,000. The application of digital and control tools under a Lean-logistics approach constitutes an effective alternative to strengthen traceability, security, and inventory reliability in the white-goods sector.

Instituciones: Universidad de Lima