Excellence in Warehouse and Inventory

Module One: Warehouse, Stores and Stock Control Management

Day One: 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

Day Two: 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

Day Three: 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.

Day Four: 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

Day Five: Stock Coding

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

Stock Recording

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

Stock Checking

• Roles and responsibility
• Requirements
• Job Descriptions
• Authority levels
• Tolerances and approvals
• The programme
• 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

Module Two: Inventory Management Techniques

Day Six: 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

Day Seven: 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

Day Eight: 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 Nine: 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

Day Ten: 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