Achieving Excellence in Warehouse and Inventory Management (10 Days)

Introduction

Effective warehousing and inventory management are critical for successful procurement and supply chain management, ensuring high-quality customer service. Properly managing warehouses and inventory helps businesses maintain optimal stock levels, reduce costs, and enhance customer satisfaction.

The Warehousing and Inventory Management Excellence course aims to provide a comprehensive understanding of warehousing principles and inventory control. Participants will explore various systems and best practices within the industry. Upon completion, participants will receive a certificate in Inventory Control and Warehouse Management, demonstrating their advanced skills and knowledge in these areas.

Objectives

The Warehouse and Inventory Management Excellence course will enable participants to:

• Understand principles of warehouse and inventory management.
• Assess existing methods and procedures.
• Evaluate operations and activities.
• Analyze key operational areas.
• Identify and understand key performance indicators (KPIs).
• Enhance workplace and personal productivity.
• Implement changes to improve customer service and reduce inventory costs.
• Minimize wasteful expenses and internal performance issues.
• Gain added value for money.
• Apply essential tools for effective warehouse and inventory management within the supply chain.

Training Methodology

• Case Studies
• Interactive Workshops
• Simulation Exercises
• Group Discussions
• Best Practice Reviews
• Role Play
• Scenario Analysis
• Expert Panels

Course Outline

Unit 1: The Purpose of Warehousing

• Definition and necessity of warehouses
• Roles and functions in the supply chain
• Trade-offs between sorting and storing
• Key questions for warehousing activity

Unit 2: The Basis of a Product Range

• Supply and demand factors
• ABC analysis (80/20 rule)
• Product handling groups
• Throughputs and product formats

Unit 3: Layout Options

• Receiving methods
• Storing methods
• Picking and assembly methods
• Dispatching methods
• Designing for activity

Unit 4: Methods and Equipment

• Types of warehouse buildings
• Loading bays and equipment
• Forklift trucks and racking
• Timing and planning for operations

Unit 5: Health and Safety

• Duty of care
• Inspection and risk assessment
• Equipment care and maintenance
• Increasing awareness

Unit 6: Security and Loss

• Reducing internal and external theft
• Actions to minimize security risks

Unit 7: Productivity and Costs

• Mixed costs and typical expenses
• Productivity, utilization, and performance measures
• Managing performance parameters

Unit 8: Service Levels

• Internal and external customer types
• Measuring customer service
• Consequences of substandard service
• Reducing errors

Unit 9: Warehouse Layout

• Advantages and disadvantages of various layouts
• Designing for movement
• Decision-making tools

Unit 10: Inventory and the Supply Chain

• Inventory control concepts
• Classification and replenishment
• Bullwhip effects and flow control
• Supply chain rules of engagement

Unit 11: Inventory Key Concepts

• Demand analysis and forecasting
• Supply lead time
• Costs and benefits
• Acquisition policies

Unit 12: Inventory Replenishment Methods and Systems

• Essential elements of inventory systems
• Stock time curve and components
• Basic and complex resupply methods
• Material Requirements Planning (MRP)

Unit 13: Stock Control-Coding

• Coding strategies
• Inventory value and overstock analysis
• Selecting optimal strategies

Unit 14: Stock Control-Recording

• Functional segregation
• Juridical aspects
• Error management

Unit 15: Stock Control – Checking

• Role management and constraints
• Job functions and authority levels
• Stock taking methods and reconciliation

Unit 16: The Performance of the Inventory

• Inventory assessment and status checks
• Inventory control strategies
• Stock targets and KPI evaluation

Unit 17: Inventory Strategies

• Push/pull systems
• Quick Response and Efficient Consumer Response
• CPFR, Lean, and Agile strategies
• Integrated collaborative supply chains

Unit 18: Improvements of Inventory or Stock

• Delivery management and theory of constraints
• Advanced stock management techniques
• Electronic ordering and information systems
• Inventory system management and planning