Warehouse Management: Strategies, Implementation, and Control (10 Days)

Introduction

Warehousing and inventory management are integral to procurement and supply chain management, crucial for delivering superior customer service. Despite often being overlooked, effective management in these areas ensures efficient stock flow and minimizes cost and service issues.

The Certified Warehouse Management Strategy and Implementation Course provides executive training on essential warehouse management skills. This comprehensive course offers industry-leading insights and hands-on training, preparing professionals for immediate application in their roles.

Upon successful completion, participants will receive a warehouse management certification, demonstrating their expertise in warehouse systems implementation, inventory control, and strategic warehouse management.

Objectives

Participants of this Warehouse Management Certification will gain the ability to:

• Assess and enhance processes, eliminate non-value-adding activities, and reduce excessive costs.
• Identify and utilize essential tools for effective warehousing and inventory management.
• Achieve world-class performance with practical skills and techniques.
• Manage internal constraints and performance issues with practical solutions.
• Understand fundamental concepts of warehouse and inventory management.
• Improve operational processes and efficiency.
• Evaluate key operational metrics and enhance personal productivity.
• Implement changes to improve customer service and reduce inventory costs.
• Eliminate waste and optimize cost management for added value.

Training Methodology

• Case studies
• Simulations
• Workshops
• Role plays
• Expert lectures
• Group discussions

Course Outline

Unit 1: The Role of the Warehouse

• Purpose and functions of a warehouse
• Services provided and requirements
• Role within the supply chain
• Balancing storage and sieving
• Key questions about warehousing activity

Unit 2: Product Classification

• Supply and demand variables
• ABC Analysis: The 80/20 rule
• Product handling groups
• Product transfers and formats

Unit 3: Layout Options

• Receiving methods
• Storage systems
• Picking and assembly
• Dispatching methods
• Floor area and height management
• Flow organization

Unit 4: Methods and Equipment

• Building supervision types
• Efficient loading bays
• Choosing the right forklift
• Selecting appropriate racking
• Warehouse design considerations
• Operational scheduling

Unit 5: Health and Safety

• Maintenance of duties
• Risk assessments
• Equipment upkeep
• Public mobilization

Unit 6: Security and Loss

• Internal theft
• External theft
• Preventative measures

Unit 7: Productivity and Costs

• Cost structures and variations
• Productivity and performance frameworks
• Setting productivity and cost targets
• Role of measurements and KPIs

Unit 8: Service Levels

• Customer satisfaction measurement
• Sampling service levels
• Impact of poor service
• Reducing errors

Unit 9: Warehouse Layout

• Advantages and disadvantages of layouts
• Ensuring effective flow
• Layout decision lists

Unit 10: Inventory and the Supply Chain

• Definition of inventory management
• Stock categories
• Demand management and replenishment
• Governing flows and supply chain rules
• Stock and statistics
• Service level definitions

Unit 11: Inventory Key Concepts

• Demand analysis
• Forecasting demand
• Supply lead time factors
• Expense versus benefit analysis
• Stock management policies and practices

Unit 12: Methods and Systems for Replenishment of Stock

• Stock systems features
• Stock time curve
• Investment and calculation methods
• Reorder point systems
• MRP/MRPII systems

Unit 13: Stock Control-Coding

• Coding styles
• Importance of goods received notes
• Detecting overstock and obsolescence
• Checklists for effective strategies

Unit 14: Stock Control-Recording

• Separation of powers
• Legal perspectives
• Causes of inaccuracies

Unit 15: Stock Control-Checking

• Roles and responsibilities
• Needs and job roles
• Levels of authority
• Check programs and stock-taking methods
• Reconciliations and discrepancies

Unit 16: Inventory Performance

• Inventory work and assessment
• Control models
• Setting stock goals
• KPI development for warehouses

Unit 17: Inventory Strategies

• Push/pull strategies
• Quick response (QR) and Efficient Consumer Response (ECR)
• Collaborative Planning, Forecasting, and Replenishment (CPFR)
• Lean and agile methods
• Quality assurance and 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 networks

Unit 18: Inventory Improvements

• Supply chain utilization
• Theory of constraints
• Practical inventory improvement approaches
• Call-offs and telemetry
• EDI and ICT
• Steps for reducing stock levels
• Inventory planning rules and models