Introduction

Warehouses and stores are often under-rated operations in organisations, yet they are essential in providing customer service. This course will teach you how to implement all of the essential tools for the effective management of warehousing and stores.

In this course you will learn how to:

• evaluate procedures, change and improve methods
• eliminate wasteful activities/costs 
• avoid all those internal problems that limit performance 
• obtain added value for money
• improve customer service
  

Duration:     5 days


Target audience
Those new to managing warehouses or stores
Those non warehouse people who need to gain an awareness of the issues and key drivers of stock control operations
Stock, Warehouse and Distribution Supervisors/Managers
Owners, operators and Directors of companies with warehouse and stores operations
 

Course Programme

Day one:  Material Management

An introduction to why we need a warehouse, what functions do they cover, how do they fit into the supply chain, including:

    To whom should the stores personnel report to?
    The balance between sorting and storing
    Twelve initial questions to ask about warehousing activity
    Balance quality and price
    Purchase material in the proper quantity
    Receive materials at the optimum time
Product Classification
It is important to establish key characteristics of the products handled as this have implications for all the warehouse operations. Such characteristics include:

• Supply /demand variables
• ABC Analysis or the 80/20 rule 
• Determining product handling groups
• Throughputs and product formats

Day two:  Store Layout and stocking methods
In examining all the operations undertaken, the balance has to be found between maximising space usage whilst minimising the time taken to carry out the operations. This involves looking at:

• Choosing a storeroom site
• Receiving options
• Storage options
• Picking / assembly options
• Despatching options 
• Using the floor and the height space
• Organising for flow
• Location Identification system

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:  Inventory and Control Procedures
Much time can be spent on this activity, but there are methods to both minimise the time and at the same time increase checking accuracy. This session examines such aspects

• Roles and Responsibility, Job Descriptions and Authority levels
• Tolerances and approvals
• Perpetual inventory
• Cycle Counts
• Annual Inventory
• Reconciliations / discrepancies
• Stock Audits
• Stores Catalogue
• Manual Control System
• Re-Order point and safety stock
• The Monte Carlo Method
• Economic Order Quantity

Stock Recording
This session looks at stock recording, a critical aspect of stock control and if done incorrectly is the source of many subsequent errors, separation of powers and legal issues.  How do we get inaccuracies?

Day four:  Stock Coding
The method by which stock is coded is important in the overall management process, this session will examine:

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

Productivity and Costs
To make operations efficient and effective, then cost control and productivity need to be managed. This session will therefore look at:

• Fixed and variable costs
• Typical costs involved
• A model for understanding the roles of productivity, utilisation, and performance 
• Setting productivity and cost targets 
• Warehouse measurements and key indications of performance
• ABC analysis

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:  Health and Safety
Warehouses are potentially dangerous areas in which to work, and an overview of the appropriate legalisation will be looked at, including:

• Duty of care
• Inspections and risk assessments-task analysis
• Equipment maintenance and care
• Recognising health and safety risks
• Raising people's awareness

Security and Loss
This session looks at minimising internal and external theft, recognising that, generally internal theft is the major problem. Preventative measures will be briefly discussed.

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 and the top 20 warehousing ideals for continuous improvement.

For further details, please email This e-mail address is being protected from spam bots, you need JavaScript enabled to view it