Course details

Overview ?

Introduction

Warehouses and Inventory Management are critical for the effective management of procurement and the supply chain to enable the efficient delivery of superior customer service.

Warehouses and Inventory controls are often overlooked and are not thought to be an important activity. Therefore, incorrect levels of inventory can be held with attendant knock on effects to costs, availability and customer service.

The program will destroy this myth of unimportance and demonstrate just how to:

Evaluate procedures, change and improve methods wasteful activities and excess costs.
Discover all of the essential tools for the effective management of warehousing and inventory
Achieve best in class performance is exactly what this program is about.
Use all of the practical skills to take back to the workplace so that all those internal problems that limit performance are avoided.
Apply the required principles and look at many practical applications in a highly interactive learning environment; delegates will have fun while learning principles and skills to ensure that they are able to change current methods and activities.

The seminar is split into two modules:

Each module is structured and can be taken as a stand-alone course; however, delegates will maximise their benefits by taking Module 1 and 2 back-to-back as a two-week seminar.

Objectives

By the end of this programme you will be able to:

Learn the principles of Warehouse and Inventory Management
Evaluate current procedures
Examine operations and activities
Analyze the key areas of operations
Identify and Understand key performance indicators
Succeed in improving operations
Improve personal productivity
Make needed changes to methods to improve customer service whilst achieving reductions in inventory
Eliminate wasteful costs
Avoid those internal problems that limit performance
Obtain added value for money
Understand and implement the essential tools for managing warehouses and inventory in the supply chain

Training Methodology

Warehouse and Inventory Management consists of nineteen modules containing lecture content, participative discussions, and many case studies to make the training come alive. The supportive comprehensive course manual will enable practical application and reinforcement and ensure back at work applications.

Organisational Impact

A legacy of increasing product availability and customer service levels is the ever-increasing requirements to:

Examine the link of stock in the company operations and activities
Analyse the key areas of warehouse operation
Identify and understand key performance indicator
Succeed in improving operation
Organisations are much more healthy and productive when they have effective warehouse and inventory operations that provide superior customer service and product availability

Personal Impact

See how to conduct an analysis of stock
Gain from making productivity improvements in all operations
Understand how to select and maintain warehouse equipment
Conduct safe working practices and operations
Apply a framework for continual improvement
Gain the financial benefits that effective warehouse and inventory management can bring

SEMINAR OUTLINE

Warehouse and Stores Management

The Role of the Warehouse

Why we need a warehouse,
What functions they cover,
How do they fit into the supply chain
The balance between sorting and storing
12 initial questions to ask about warehousing activity

Product Classification

Supply /demand variables
ABC Analysis or the 80/20 rule
Determining product handling groups
Throughputs and product formats

Layout Options

Receiving options
Storage options
Picking/assembly options
Dispatching options
Using the floor and the height space
Organising for flow

Methods and Equipment

Here we specifically look at the lifting, storing and moving equipment available for specific layout options, including:

Warehouse structures
Loading bays
Selecting fork lift trucks
Selecting racking
Implications for warehouse layouts
Operational timings and planning

Health and Safety

Duty of care
Inspections and risk assessments-task analysis
Equipment maintenance and care
Raising people's awareness

Security and Loss

Minimizing internal theft
Minimizing external theft
Preventative measures will be briefly discussed.

Productivity and Costs

Fixed and variable cost
Typical costs involved
A model for understanding the roles of productivity, utilisation, and performance
Setting productivity and cost targets
The importance of having measurements and key indications of performance

Service Levels

As Warehouses are a link in the total process of satisfying customers, this session will therefore look at:

Internal and external customers
The three key customer service measure
Customer service sampling
Effects of substandard service
Minimising errors

Warehouse Layout

Different types of layout with advantages and disadvantages
Planning for flow in the warehouse
Checklists to help on deciding the best option

Summary

Finally, in linking together all the sessions, we put forward simple overviews and a clear summary, including:

The 7 step model for better warehouse management
The top 20 warehousing ideals for continuous improvement

Inventory and the Supply Chain

Inventory management definition
Types of stock
Demand amplifications
Demand replenishment in networks
Managing the flows
Type I and II supply chains
The Supply Chain Rules
Inventory and statistics
Concept of service level

Inventory Key Concepts

Key Component: Demand Analysis
Key Component: Demand Forecasting
Key Component: Supply Lead Time
Key Component: Cost & Benefits
Inventory benefits
Inventory polices
Inventory in organizations

Inventory Replenishment Methods and Systems

Basic mechanics of inventory systems
The stock time curve
Stock components
Stock investment
Free stock calculation
Simple replenishment methods, for example, Min/Max
Accurate replenishment methods, for example, Reorder Point and Reorder Level (ROP/ROL)
Requirements planning systems, for example, Materials/Manufacturing Resource/Requirements Planning (MRP / MRPII)

Stock Control-Coding

Different coding methods
Importance of inventory receipts
Identifying surplus and obsolescent stock
Checklists to help on deciding the best option

Stock Control-Recording

Separation of powers
Legal issues
How do we get inaccuracies?

Stock Control-Checking

Roles and responsibility
Requirements
Job Descriptions
Authority levels
Tolerances and approvals
The stock check programme
Options for stock checking methods
Reconciliations / discrepancies

Inventory Performance

Inventory Performance
Assessing the stock level
Models for implementing inventory control
Determining stock targets
Inventory questions
Inventory KPI's in warehouses/stores

Inventory Strategies

Push/pull
Quick response (QR)
Efficient consumer response (ECR)
Collaborative planning forecasting and replenishment (CPFR)
Lean and agile approaches
Quality Management
Postponement
Cross Docking
Consolidation
Vendor Managed Inventory (VMI)
Consignment stocking
Co Managed Inventory (CMI)
Direct product profitability (DPP)
Economic value added (EVA)
Collaborative supply chains

Inventory Improvements

Using the Supply Chain
Using the Theory of Constraints
Practical inventory improvements
Call offs and Telemetry
EDI and ICT
Keys to reducing stock levels
The 7 Rules for planning inventory
Model for planning inventory

Day 1

Day 2

Day 3

Day 4

Day 5

Training Methodology

Warehouse Management: Strategy, Implementation & Control

Course details

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