Aplicação de filosofia kaizen para reduzir custo com logística reversa em um centro de distribuição do nicho de linha branca

Abstract

Founded in 1911 in Benton Harbor, Michigan, USA, the company under study is a leading player in the home appliances sector, offering products such as refrigerators, washing machines, and stoves. The organization faces logistical challenges, particularly with reverse logistics, where damaged products are returned to the factories. In 2022, return freight costs amounted to R$ 195,000.00, primarily due to the accumulation of products with damaged packaging at its distribution center in Alhandra – PB. This case study analyzes the implementation of a rework area within this distribution center, aimed at reducing reverse logistics costs by allowing damaged-packaged products to be reconditioned locally. The study also examines the quality control process flow of the products, from receipt through to storage in the return stock at this distribution center. The implementation followed the Kaizen philosophy, employing continuous improvement tools to optimize processes. As a result, there was a 30% reduction in return freight costs, demonstrating the effectiveness of the Kaizen approach and quality tools in logistics. This rework model, in addition to reducing operational costs, enhanced quality control and can be replicated across other company distribution centers, highlighting its strategic role