{"id":4939,"date":"2026-09-05T17:07:58","date_gmt":"2026-09-05T15:07:58","guid":{"rendered":"https:\/\/www.makeitalia.com\/case-studies\/warehouse-management-reducing-stock-and-optimizing-orders\/"},"modified":"2026-10-06T12:13:26","modified_gmt":"2026-10-06T10:13:26","slug":"warehouse-management-reducing-stock-and-optimizing-orders","status":"publish","type":"case-study","link":"https:\/\/www.makeitalia.com\/en\/case-studies\/warehouse-management-reducing-stock-and-optimizing-orders\/","title":{"rendered":"Warehouse Management: Reducing Stock and Optimizing Orders"},"content":{"rendered":"<h1>Warehouse management: optimizing procurement and reducing stock and shortages <\/h1>\n<div>\n<p>Case Study: optimizing procurement to reduce stock, avoid shortages, and improve material management in production.<\/p>\n<\/p><\/div>\n<ul>\n<li>\n<div>Automotive<\/div>\n<\/li>\n<li>\n<div>Logistics<\/div>\n<\/li>\n<\/ul>\n<p><img decoding=\"async\" src=\"\/wp-content\/uploads\/2026\/09\/Case-study-sia-pagina-generale-sia-in-tutti-i-case-study-specifici-1.jpeg\" alt=\"Grafica astratta con tre icone circolari illuminate disposte in fila orizzontale, rappresentante i case study.\"><\/p>\n<div>The Context<\/div>\n<h2>Unstructured warehouse management<\/h2>\n<div>\n<p>The reason the client contacted us was that they had a set of approximately 3,000 SKUs in the warehouse, managed visually by operators. This system generated significant issues: production shortages, overstocking caused by incorrect planning, and a high number of inefficiently generated orders. Our goal in this project was clear: to define and implement an effective procurement policy capable of resolving existing criticalities, improving production logistics, and material control.<\/p>\n<\/div>\n<div>The Project<\/div>\n<h2>Defining an effective procurement management model<\/h2>\n<div>\n<p>The project introduced structured logic for material management, improving the balance between stock, shortages, and operational activities.<\/p>\n<\/div>\n<ul>\n<li>\n<h3>Client Industry<\/h3>\n<div>\n<p>Company active in the automotive sector, with approximately 3,000 SKUs managed in the warehouse and a need to improve material management.<\/p>\n<\/div>\n<\/li>\n<li>\n<h3>Initial Situation<\/h3>\n<div>\n<p>Procurement based on experience and visual logic, without a structured planning system.<\/p>\n<\/div>\n<\/li>\n<li>\n<h3>Critical Issues Identified<\/h3>\n<div>\n<p>Excess stock and frequent material shortages, with impacts on production and costs.<\/p>\n<\/div>\n<\/li>\n<li>\n<h3>Project Objectives<\/h3>\n<div>\n<p>Defining effective policies to improve material control and production continuity.<\/p>\n<\/div>\n<\/li>\n<\/ul>\n<div>Solution<\/div>\n<h2>Definition of procurement policies and parameters<\/h2>\n<div>\n<p>We intervened with a structured approach, starting from the analysis of consumption and the characteristics of the materials managed in the warehouse. Based on these analyses, we defined specific procurement policies, distinguishing between requirement-based management and controlled stock management. For stock-managed SKUs, we introduced parameters such as procurement lot, safety stock, and reorder point. The identified solutions were validated through a simulator we developed, which allowed for the evaluation of different scenarios in terms of stock levels, shortage frequency, and number of orders. Once the optimal configuration was identified, we implemented the parameters within the company&#8217;s management system, making the model operational and integrated into the processes.<\/p>\n<\/div>\n<div>Project Phases<\/div>\n<h2>Analysis, policy definition, implementation<\/h2>\n<div>\n<p>The project developed through data analysis, the definition of procurement policies, and the implementation of parameters in the management system.<\/p>\n<\/div>\n<ul>\n<li>\n<p>        <img decoding=\"async\" src=\"\/wp-content\/uploads\/2026\/07\/1-di-3.svg\" alt=\"\"><\/p>\n<h3>Step 1<\/h3>\n<p>Analysis<\/p>\n<div>\n<h3 class=\"esc-step-title\">Consumption study<\/h3>\n<p>Analysis of consumption and material characteristics to define management logic.<\/p>\n<\/div>\n<p><a href=\"#\"><\/a><\/p>\n<\/li>\n<li>\n<p>        <img decoding=\"async\" src=\"\/wp-content\/uploads\/2026\/07\/2-di-3.svg\" alt=\"\"><\/p>\n<h3>Step 2<\/h3>\n<p>Definition<\/p>\n<div>\n<h3 class=\"esc-step-title\">Management policies<\/h3>\n<p>Introduction of requirement-based and stock-based management with specific logistical parameters.<\/p>\n<\/div>\n<p><a href=\"#\"><\/a><\/p>\n<\/li>\n<li>\n<p>        <img decoding=\"async\" src=\"\/wp-content\/uploads\/2026\/07\/3-di-3.svg\" alt=\"\"><\/p>\n<h3>Step 3<\/h3>\n<p>Implementation<\/p>\n<div>\n<h3 class=\"esc-step-title\">System parameters<\/h3>\n<p><span data-sheets-root=\"1\">Configuration of parameters in the management system and launch of the new operating model.<\/span><\/p>\n<\/div>\n<p><a href=\"#\"><\/a><\/p>\n<\/li>\n<\/ul>\n<hr>\n<div>Results<\/div>\n<h2>Stock reduction and guaranteed material availability<\/h2>\n<div>\n<p>The project improved warehouse management, allowing for a reduction in stock levels and ensuring material availability without increasing operational effort.<\/p>\n<\/div>\n<div>Outputs Obtained<\/div>\n<h2>Project Deliverables<\/h2>\n<ul>\n<li>\n<h3>-20% stock<\/h3>\n<div>\n<p>Reduction in the total value of inventory, thanks to optimized procurement policies.<\/p>\n<\/div>\n<\/li>\n<li>\n<h3>Zero shortages<\/h3>\n<div>\n<p>Elimination of material shortages, even during periods of peak demand.<\/p>\n<\/div>\n<\/li>\n<li>\n<h3>Unchanged effort<\/h3>\n<div>\n<p>The operational workload of the purchasing department remained unchanged, despite a significant improvement in performance.<\/p>\n<\/div>\n<\/li>\n<li>\n<h3>Greater control<\/h3>\n<div>\n<p>More structured material management and greater visibility into procurement dynamics.<\/p>\n<\/div>\n<\/li>\n<\/ul>\n<div>Related Case Studies<\/div>\n<h2>Discover Other Projects<\/h2>\n<ul>\n<li>\n<\/li>\n<li>\n<\/li>\n<li>\n<\/li>\n<\/ul>\n<h2>Do You Have a Similar Challenge?<\/h2>\n<div>Optimize your warehouse management and reduce floor stock and shortages with a concrete project based on data and structured processes.<\/div>\n<p><p>\n        <a href=\"https:\/\/www.makeitalia.com\/en\/contact-us\/\">CONTACT US<\/a>\n    <\/p>\n<\/p>\n<p><!--more--><br \/>\n<!-- {\"type\":\"layout\",\"children\":[{\"type\":\"section\",\"props\":{\"image_position\":\"center-center\",\"style\":\"default\",\"title_breakpoint\":\"xl\",\"title_position\":\"top-left\",\"title_rotation\":\"left\",\"vertical_align\":\"middle\",\"width\":\"default\"},\"children\":[{\"type\":\"row\",\"props\":{\"column_gap\":\"large\",\"layout\":\"2-3,1-3\",\"row_gap\":\"large\"},\"children\":[{\"type\":\"column\",\"props\":{\"image_position\":\"center-center\",\"position_sticky_breakpoint\":\"m\",\"width_medium\":\"2-3\"},\"children\":[{\"type\":\"headline\",\"props\":{\"content\":\"Warehouse management: optimizing procurement and reducing stock and shortages \",\"image_align\":\"left\",\"image_margin\":\"xsmall\",\"title_element\":\"h1\",\"title_style\":\"heading-xlarge\"}},{\"type\":\"text\",\"props\":{\"class\":\"esc-text-padding-left-large\",\"column_breakpoint\":\"m\",\"content\":\"\n\n<p>Case Study: optimizing procurement to reduce stock, avoid shortages, and improve material management in production.<\/p>\n\n \",\"margin_bottom\":\"default\",\"margin_top\":\"default\",\"maxwidth\":\"2xlarge\"}}]},{\"type\":\"column\",\"props\":{\"image_position\":\"center-center\",\"position_sticky_breakpoint\":\"m\",\"vertical_align\":\"bottom\",\"width_medium\":\"1-3\"},\"children\":[{\"type\":\"button\",\"props\":{\"grid_column_gap\":\"\",\"grid_row_gap\":\"small\",\"margin_bottom\":\"default\",\"margin_top\":\"default\",\"status\":\"disabled\",\"text_align\":\"right\",\"text_align_breakpoint\":\"m\",\"text_align_fallback\":\"left\"},\"children\":[{\"type\":\"button_item\",\"props\":{\"button_style\":\"primary\",\"content\":\"Pulsante 1\",\"dialog_layout\":\"modal\",\"dialog_offcanvas_flip\":true,\"icon_align\":\"left\",\"link\":\"#\"}},{\"type\":\"button_item\",\"props\":{\"button_style\":\"text\",\"content\":\"Pulsante 2\",\"dialog_layout\":\"modal\",\"dialog_offcanvas_flip\":true,\"icon_align\":\"left\",\"link\":\"#\"}}]},{\"type\":\"list\",\"props\":{\"class\":\" esc-chips esc-text-padding-left\",\"column_breakpoint\":\"m\",\"image_align\":\"left\",\"image_svg_color\":\"emphasis\",\"image_vertical_align\":true,\"list_element\":\"ul\",\"list_horizontal_separator\":\", \",\"list_type\":\"vertical\",\"show_image\":true,\"show_link\":true},\"children\":[{\"type\":\"list_item\",\"props\":{\"content\":\"Automotive\"}},{\"type\":\"list_item\",\"props\":{\"content\":\"Logistics\"}}],\"name\":\"chips case \"}]}]}],\"name\":\"06 ESC Section 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Context\",\"image_align\":\"left\",\"image_margin\":\"xsmall\",\"title_element\":\"div\",\"title_style\":\"text-meta\"}}]},{\"type\":\"column\",\"props\":{\"image_position\":\"center-center\",\"position_sticky_breakpoint\":\"m\",\"width_medium\":\"2-3\"},\"children\":[{\"type\":\"headline\",\"props\":{\"content\":\"Unstructured warehouse management\",\"image_align\":\"left\",\"image_margin\":\"xsmall\",\"title_element\":\"h2\",\"title_style\":\"heading-large\"}},{\"type\":\"text\",\"props\":{\"class\":\"esc-text-padding-left\",\"column_breakpoint\":\"m\",\"content\":\"\n\n<p>The reason the client contacted us was that they had a set of approximately 3,000 SKUs in the warehouse, managed visually by operators. This system generated significant issues: production shortages, overstocking caused by incorrect planning, and a high number of inefficiently generated orders. Our goal in this project was clear: to define and implement an effective procurement policy capable of resolving existing criticalities, improving production logistics, and material control.<\/p>\n\n\",\"margin_bottom\":\"default\",\"margin_top\":\"default\"}}]}]}],\"name\":\"06 ESC Section Intro\"},{\"type\":\"section\",\"props\":{\"image_position\":\"center-center\",\"style\":\"muted\",\"title_breakpoint\":\"xl\",\"title_position\":\"top-left\",\"title_rotation\":\"left\",\"vertical_align\":\"middle\",\"width\":\"default\"},\"children\":[{\"type\":\"row\",\"props\":{\"column_gap\":\"large\",\"layout\":\"1-3,2-3\",\"row_gap\":\"large\"},\"children\":[{\"type\":\"column\",\"props\":{\"image_position\":\"center-center\",\"position_sticky_breakpoint\":\"m\",\"width_medium\":\"1-3\"},\"children\":[{\"type\":\"headline\",\"props\":{\"class\":\"esc-custom-title-line\",\"content\":\"The 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Objectives\"}}],\"props\":{\"block_align\":\"center\",\"column_breakpoint\":\"m\",\"layout\":\"grid-2\",\"list_element\":\"ul\",\"list_style\":\"divider\",\"margin_bottom\":\"default\",\"margin_top\":\"default\",\"meta_align\":\"below-title\",\"meta_style\":\"text-meta\",\"show_content\":true,\"show_link\":true,\"show_meta\":true,\"show_title\":true,\"title_colon\":false,\"title_element\":\"h3\",\"title_font_family\":\"secondary\",\"title_grid_breakpoint\":\"m\",\"title_grid_column_gap\":\"large\",\"title_grid_row_gap\":\"large\",\"title_grid_width\":\"medium\",\"title_style\":\"heading-small\"}}]}]}],\"name\":\"24  ESC Section intro +  Feature List  (senza media)\"},{\"type\":\"section\",\"props\":{\"image_position\":\"center-center\",\"style\":\"default\",\"title_breakpoint\":\"xl\",\"title_position\":\"top-left\",\"title_rotation\":\"left\",\"vertical_align\":\"middle\",\"width\":\"default\"},\"children\":[{\"type\":\"row\",\"props\":{\"column_gap\":\"large\",\"layout\":\"1-3,2-3\",\"row_gap\":\"large\"},\"children\":[{\"type\":\"column\",\"props\":{\"image_position\":\"center-center\",\"position_sticky_breakpoint\":\"m\",\"width_medium\":\"1-3\"},\"children\":[{\"type\":\"headline\",\"props\":{\"class\":\"esc-custom-title-line\",\"content\":\"Solution\",\"image_align\":\"left\",\"image_margin\":\"xsmall\",\"title_element\":\"div\",\"title_style\":\"text-meta\"}}]},{\"type\":\"column\",\"props\":{\"image_position\":\"center-center\",\"position_sticky_breakpoint\":\"m\",\"width_medium\":\"2-3\"},\"children\":[{\"type\":\"headline\",\"props\":{\"content\":\"Definition of procurement policies and 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Based on these analyses, we defined specific procurement policies, distinguishing between requirement-based management and controlled stock management. For stock-managed SKUs, we introduced parameters such as procurement lot, safety stock, and reorder point. The identified solutions were validated through a simulator we developed, which allowed for the evaluation of different scenarios in terms of stock levels, shortage frequency, and number of orders. 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reduction and guaranteed material availability\",\"image_align\":\"left\",\"image_margin\":\"xsmall\",\"title_element\":\"h2\",\"title_style\":\"heading-large\"}},{\"type\":\"text\",\"props\":{\"class\":\"esc-text-padding-left\",\"column_breakpoint\":\"m\",\"content\":\"\n\n<p>The project improved warehouse management, allowing for a reduction in stock levels and ensuring material availability without increasing operational effort.<\/p>\n\n\",\"margin_bottom\":\"default\",\"margin_top\":\"default\"}}]}]}],\"name\":\"06 ESC Section 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procurement to reduce stock, avoid shortages, and improve material management in production. Automotive Logistics The Context Unstructured warehouse management The reason the client contacted us was that they had a set of approximately 3,000 SKUs in the warehouse, managed visually by operators. This [&hellip;]<\/p>\n","protected":false},"author":3,"featured_media":4934,"template":"","class_list":["post-4939","case-study","type-case-study","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.6 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Warehouse Management, Reducing Stock and Optimizing Orders: Case Study | Makeitalia<\/title>\n<meta name=\"description\" content=\"Warehouse Management: discover the Makeitalia approach to reducing stock, eliminating shortages, and making the Supply Chain efficient.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.makeitalia.com\/en\/case-studies\/warehouse-management-reducing-stock-and-optimizing-orders\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta 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