Effective Warehouse Operations and Inventory Management

Introduction

To run a productive and efficient warehouse and distribution operation is a challenging task. There are many different aspects of the operation which must be proficiently managed and well-coordinated.

This Course Will Discuss How To:

• Increase Warehouse Operations Productivity
• Streamline The Flow Of Materials And Provide Superior Service
• Effectively Manage Distribution Operations
• Motivate And Manage Warehouse Personnel

Inventory Management Techniques an intensive five-day course, for those who want to understand and implement the essential tools for managing inventory in the supply chain, Participants are shown how to evaluate procedures and make needed changes to methods to improve customer service whilst achieving reductions in inventory; eliminate wasteful costs; avoid internal problems that limit performance; obtain added value for money.

Objectives

By the end of the programme participants will be able to:

• To examine the most effective warehousing practices
• To analyze methods for improving warehousing operation
• To study different inventory control systems
• To explore new methods in inventory management
• To consider efficient management of distributionarehouse Operation and Ianagement
• To understand proper use of Incoterms
• To provide insights into motivation of warehouse personnel
• To review methods of warehouse personnel performance appraisal
• How to analyze stock and inventory
• How to make productivity improvements
• Understand the role of inventory in the supply chain
• Balancing cost and service requirements
• A framework for continual improvement
• Best in class practices

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This course will be of benefit to all supervisors in warehousing, inventory management and logistics operations. It will also be of benefit to managers in these operations.

Course Outline

Module 1: Warehouse Space Management

• Warehouse layout design – sizing the space requirement
• Key Factors to consider during warehouse sizing
• Order Picking: Methods for Piece Pick, Case Pick, and Pallet Pick
• Operations.
• Racking Complex - Narrow Aisle - Roller Racking - Free Standing -
• Block Storage
• Design inbound and outbound material flow
• Computer warehouse management system
• Warehouse layout
• Material handling equipment specifications
• Cost-effective warehouse review
• Materials Flow effectiveness.
• Use of put & drop location techniques to keep things moving.
• Storage methods and efficiency of space utilization.
• Workflow management by making everything visible on the floor.
• Stock keeping and traceability.
• Stock accuracy and cycle counting.
• Goods inwards and outwards consolidation areas
• Palletization methods for protection of goods in storage or transit.
• Vehicle loading practices and vehicle space utilization.
• Cross-docking
• Increasing turn over instead of warehousing
• How to maximize warehouse space while expansion is not an option

Module 2: Managing the Warehouse

• Warehouse operations management
• Warehouse management systems
• Planning warehouse layout
• Utilization of storage aid
• Managing special storage requirements
• Controlling the warehouse item location
• Managing shipping and receiving operations
• Shelf-life management

Module 3: Warehouse Inventory Management

• Measuring warehousing productivity
• Providing excellent customer service
• Overcoming barriers to warehouse performance
• Achieving effective inventory control
• EOQ and MRP inventory systems
• Just in time inventory management
• Utilizing consignment inventory
• Reducing costs in inventory management
• Improving the flow of materials
• Controlling backorder levels
• ABC analysis
• Achieving improved inventory accuracy
• Managing local trucking operations
• Managing international transportation operations
• Proper utilization of Incoterms
• Selection of transportation service companies SAP MM Module
• Improving Warehouse Operation with SAP
• How MM Module can Improve warehouse Operation
• Reports of the MM Module (Optional)

Module 4: Inventory costs and service

• Why hold stock?
• Inventory costs
• Service levels from inventory
• Cost/service trade-offs
• Understanding Lead time
• Lead time variability and uncertainty
• Inventory and statistics

How much stock should be held?

• Stock time curve
• Determining the Reorder level
• Determining the Reorder point
• Carrying safety stock
• Fixed and variable time periods
• Fixed and variable order quantities

Replenishment methods for independent demand

• When to order
• How much to order
• Economic order quantities
• Two bin methods
• Minimum - maximum methods
• Comparing continuous review and periodic review methods

Module 5: Other Replenishment methods

• When to order for dependant demand
• How much to order for dependant demand
• Materials planning (MRP and MRPII)
• For spare parts

Demand Forecasting

• Sales forecasts
• Statistical forecasts
• When forecasting is easier
• When forecasting is harder

Stock coding

The method by which stock is coded is important in the overall management process, this session will examine:

• Different methods
• Understanding of all involved
• Checklists to help on deciding the best option

Stock Recording

This session looks at stock recording, a critical aspect of stock control and if done incorrectly is the source of many subsequent errors

• Separation of powers
• Legal issues
• How do we get inaccuracies?

Stock Checking

Much time can be spent on this activity, but there are methods to both minimize the time and at the same time increase checking accuracy. This session examines such aspects

• Roles and Responsibility
• Requirements
• Job Descriptions
• Authority levels
• Tolerances and approvals
• The program
• Options
• Reconciliations / discrepancies

Model for planning inventory

• Managing inventory by value and by volume
• Questions to ask about the inventory of Model for inventory planning