Effective Warehouse and Logistic Management

Introduction

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.

• 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

Objectives

Above all, this program will help you internalize superior warehouse, inventory management skills, and put them to work back in your workplace
This course aims to enable participants to develop the following competencies:

• Analyzing costs and lead times
• Understanding of the link of warehousing and inventory in the supply chain and its interactive components
• Changing current methods to optimize cost and serve trade-offs
• Improving current methods
• Sharing different approaches with all stakeholders for mutual gain
• Discussing, listening, and understanding the point of view of others

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 practices. 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 program is for all individuals who have a stake in the Supply Chain and all Logistics, Materials, Inventory, Stock, Warehouse and Distribution Professionals
• It will also help those who need to develop their limited understanding of Warehouse and Inventory management
• It will be especially helpful to all those who are looking to make business gains and benefits and to any owners, operators, and directors of companies with warehouse and stores operations and who hold stock and inventory

Course Outline

Day 1: The Role of the Warehouse
An introduction to why we need a warehouse, what functions do they cover, how do they fit into the supply chain including:

• The balance between sorting and storing
• 12 initial questions to ask about warehousing activity

Product Classification
It is important to establish key characteristics of the products handled as this have implications for all the warehouse operations. Such characteristics include:

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

Layout Options
In examining all the operations undertaken, the balance has to be found between maximizing space usage whilst minimizing the time taken to carry out the operations. This involves looking at:

• Receiving options
• Storage options
• Picking/assembly options
• Despatching 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 forklift trucks
• Selecting racking
• Implications for warehouse layouts
• Operational timings and planning

Day 2: Health and Safety
Warehouses are potentially dangerous areas in which to work, and an overview of the appropriate legalization will be looked at, including:

• Duty of care
• Inspections and risk assessments-task analysis
• Equipment maintenance and care
• Raising peoples awareness

Security and Loss
This session looks at minimizing internal and external theft, recognizing that, generally internal theft is the major problem. Preventative measures will be briefly discussed.
Productivity and Costs
To make operations efficient and effective, then cost control and productivity need to be managed. This session will therefore look at:

• Fixed and variable cost
• typical costs involved
• A model for understanding the roles of productivity, utilization, 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
• Minimizing errors

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 in deciding the best option.
• 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

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

Day 3: 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 policies
• Inventory in organizations

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 forklift trucks
• Selecting racking
• Implications for warehouse layouts
• Operational timings and planning

Day 4: Inventory Replenishment Methods and Systems

• Basic mechanics of inventory systems
• The stock time curve
• Stock components
• Stock investment
• Free stock
• Fixed order quantity systems
• Fixed order time cycle systems
• Requirements planning systems

Stock Control and Checking

• Inventory receipts
• Identifying inventory
• Surplus and obsolescent stock
• Stock control and records
• Stock checking programs
• Reviewing current procedures and policies

Day 5: Inventory Performance

• Inventory Assessment
• 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

• The Supply Chain and the Theory of Constraints
• Practical inventory improvements
• Keys to reducing stock levels
• Rules for planning inventory
• Model for planning inventory

To Evaluate the effectiveness of training there would be Pre Training& Post Training MCQ Test.