Excellence in Warehouse and Inventory

• Why we need a warehouse?
• What functions they cover?
• How do they fit into the supply chain?
• The Balance between Sorting and Storing
• The Location and Capacity of Warehouses

Product Classification

• Supply / Demand Variables
• ABC Analysis or the 80/20 Rule
• Determining Product Handling Groups
• Throughputs and Product Formats

• Receiving Options
• Storage Options
• Picking / Assembly Options
• Dispatching Options
• Using the Floor and the Height Space
• Organising for Flow

Methods and Equipment

Equipment required for lifting, storing and moving equipment available for specific layout options, including:

• Loading Bays
• Selecting Fork Lift Trucks
• Selecting Racking
• Implications for Warehouse Layouts
• Operational Timings and Planning
• The Use of IT within the Warehouse

• 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

• Fixed and Variable Costs
• 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 also examine:

• Internal and External Customers
• Customer Service Measure
• Customer Service Sampling
• Effects of Substandard Service
• Minimising Errors

• Different Types of Layout with Advantages and Disadvantages
• Planning for Flow in the Warehouse
• Calculations for Storage
• Calculations for throughput and Productivity
• Checklists to help on deciding the best option to take back to the participants’ workplace

• Inventory Definitions and Importance
• Inventory Flow in the Supply Chain
• The Basic Rules of Successful Supply Chain
• Supply Chain and Inventory Dynamics
• Financial Management and Inventory
• Statistics Application in Inventory Control
• Truths on Inventory Visibility

• End-User Demand Analysis
• Forecasting for Operations and Maintenance
• Understanding Supply Lead Time
• Cost & Benefits Analysis
• Developing Inventory Policies
• The Need for Inventory in Organizations

• Basic Mechanics of Inventory Systems
• Establishing Order Quantity
• Implications of Free Stock in Inventory
• Simple Replenishment Methods, for example, Min / Max
• Replenishment Methods, Reorder Point and Reorder Level (ROP / ROL)
• Requirements Planning Systems, Bills of Material and Inventory Planning
• Class Assignment Inventory Control Methods

• Establishing Stock Checking
• Developing Stock Accuracy
• Stock Tolerances and Approvals
• Stock Reconciliations / Discrepancies
• Identifying Surplus and Obsolescent Stock
• Identifying Different Storage Conditions
• Understanding Stock Coding
• Stock Variety Reductions

• Creating Inventory Policy
• Incoterms and the Supply Chain Rules
• Understanding Vendor Managed Inventory (VMI) and Co Managed Inventory (CMI)

Inventory Improvements

• Using the Supply Chain
• Using the Theory of Constraints
• Practical Inventory Improvements
• Keys to Reducing Stock Levels
• Model for Planning Inventory