ANALYSIS OF THE IMPACTS OF INTEGRATION BETWEEN INVENTORY, PRODUCTION, AND COSTS: A CASE STUDY IN THE PLASTICS PROCESSING INDUSTRY OF THE MANAUS FREE TRADE ZONE

Abstract

The integration of inventory management, production planning, and cost control processes is a strategic factor for industrial competitiveness, contributing to waste reduction, productivity improvement, and optimization of operational performance. In this context, the present study aimed to analyze the impacts of integrating inventory, production, and cost management on the performance of a plastics manufacturing company, fictitiously named Amazônia Plásticos, located in the Manaus Free Trade Zone, Brazil. The research is characterized as applied, with a mixed-methods (qualitative and quantitative) approach, exploratory and descriptive objectives, and was conducted through a case study. Data were collected through semi-structured interviews, direct observation of production processes, and documentary analysis of production reports, inventory records, operational indicators, and cost control reports. To support data analysis, Industrial Engineering tools were employed, including the Ishikawa Diagram, Pareto Chart, PDCA cycle, and the 5W2H action plan. The results showed that deficiencies in the integration of these processes lead to inventory discrepancies, raw material losses, rework, production downtime, and increased operating costs. The proposed improvements demonstrated the potential to enhance inventory accuracy, reduce waste, and improve process efficiency. It is concluded that the integration of inventory, production, and cost management is a key factor in improving the company's operational and economic performance, strengthening its competitiveness and supporting managerial decision-making.