Managing Warehouse Operations

Introduction:

This Warehouse Operations and Management course is designed for professionals seeking to gain essential skills and competency in warehouse management. Participants will develop a comprehensive understanding of warehouse operations management, enabling them to effectively handle the complex responsibilities of a warehouse operations manager. Efficient warehousing and inventory management are crucial for organizations to ensure timely delivery of goods to customers, maintaining quality and meeting deadlines. Ineffective control of warehouse operations can lead to issues such as stockouts, increased costs, and diminished customer satisfaction.

Objectives:

By the end of this Warehouse Operations and Management course, participants will be able to:

• Assess and refine processes to eliminate waste and minimize costs.
• Utilize specialized tools for effective warehouse operations.
• Implement best practices in planning and managing warehouse operations.
• Apply hands-on skills to optimize warehouse settings and address performance deficiencies.
• Understand the basic concepts of Warehouse and Inventory Management.
• Optimize operation flows to avoid delays and service cuts.
• Demonstrate critical thinking and understanding of warehouse operations.
• Comprehend performance measures essential for successful warehouse management.
• Develop strategies to enhance operational performance and value delivery.
• Maximize individual performance and efficiency in warehouse management roles.
• Improve customer service while managing inventory levels.
• Eliminate unnecessary expenses and figures.
• Formulate procedures to prevent internal delays.
• Achieve more with less cost.
• Understand and apply basic warehouse and inventory management concepts within the supply chain.

Training Methodology:

• Group discussions
• Simulation exercises
• Guest speakers
• Interactive workshops
• Site visits
• Assessment and feedback

Course Outline:

Unit 1: The Role of the Warehouse

• Appreciate the importance of warehouses.
• Explain the functions performed by warehouses.
• Integrate warehouses efficiently into the supply chain.
• Balance sorting and storage functions.
• Ask preliminary questions about warehouse activities.

Unit 2: Product Classification

• Assess supply and demand aspects.
• Apply ABC analysis or the 20/80 principle.
• Identify product handling groups for optimal space usage.
• Examine throughputs and product forms to enhance operations.

Unit 3: Inventory and the Supply Chain

• Discuss inventory management in the supply chain context.
• Explore different types of stock and their implications.
• Understand demand amplification and its impact.
• Influence demand replenishment in virtual networks.
• Flow management
• Class I and II supply chains
• Supply chain policy
• Inventory and statistics
• Concept of service level
• Demand analysis
• Demand planning
• Supply lead-time
• Cost and benefits
• Inventory advantages
• Inventory policies
• Role of inventories in organizations

Unit 4: Inventory Replenishment Methods and Systems

• Investigate fundamental operations of inventory systems.
• Observe stock time curves and their significance.
• Analyze stock and investment factors.
• Calculate available stock.
• Determine frequencies for basic and effective approval processes.
• Learn basic replenishment methods (e.g., Min/Max).
• Understand Reorder Point (ROP) and Reorder Level (ROL) methods.
• Implement requirements planning systems (e.g., MRP/MRPII).

Unit 5: Stock Control – Recording and Coding

• Explore different coding systems.
• Ensure accurate inventory receipts.
• Document remaining and obsolete products.
• Use checklists for better decision-making.
• Implement internal segregation of duties.
• Address legal matters.
• Identify sources of incorrect information.

Unit 6: Stock Control – Checking

• Define tasks and responsibilities.
• Outline requirements and job descriptions.
• Establish levels of authority and tolerances/approvals.
• Develop a stock counting program.
• Apply various methods for stocktaking.
• Reconcile discrepancies.

Unit 7: Additional Topics

• Assess inventory performance.
• Organize inventory controls.
• Establish stock levels.
• Address inventory-related questions.
• Review Key Performance Indicators (KPIs) related to inventory, particularly in warehouses/stores.