Excellence in Warehouse and Inventory



OBJECTIVES

By the end of this Excellence in Warehouse and Inventory Management training course, delegates 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

Outline

Module 1: Warehouse & 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
  • 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

 

 
Layout Options
  • 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

 

 
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 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

 

 
Warehouse Layouts and Productivity
  • 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
Module 2: Inventory & Stock Control Management
 
Inventory and the Supply Chain
  • 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
 
Key Components to Understanding Effective Inventory Control
  • 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
 
Inventory Mechanics, Methods and Systems
  • 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 Control
  • 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
 
Understanding Inventory Strategies
  • 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

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