INVENTORY RISK MANAGEMENT. By: John Kemuel C. Ricofuerto Sales Consultant Iris N. Lumbao Solutions Delivery Manager

Transcription

1 INVENTORY RISK MANAGEMENT By: John Kemuel C. Ricofuerto Sales Consultant Iris N. Lumbao Solutions Delivery Manager

2 AGENDA: I. What Is Inventory Management II. Why Inventory Management III. What are the Risk in Inventory IV. Basic Inventory Planning and Control Functions V. Classification of Materials VI. Inventory Costing VII. Inventory Systems VIII.Common Inventory Problems IX. Solution and Recommendations

3 What is Inventory Management?

4 Inventory Management The process of determining the optimal quantity and timing of inventory for the purpose of aligning it with sales and production capacity. Inventory Management has a direct impact a company's cash flow and profit margins especially for smaller businesses that rely upon a quick turnover of goods or materials.

5 Why Inventory Management? Customer Satisfaction Forecasting Controlling Cost Optimal Storage

6 Elements of Inventory Management Types of Inventories Raw materials Purchased parts and supplies Finished Goods Work-in-process (partially completed products ) Items being transported Tools and equipment Goods-in-transit to warehouses or customers Scraps

7 Elements of Inventory Management

8 What are the risks in Inventory? Theft/Inventory Loss Inventory Waste Damage Shelf Life Life Cycle

9 Basic Inventory Management Functions Recording Report Monitoring

10 Basic Inventory Management Functions Recording Reporting Monitoring

11 Basic Inventory Management Functions Recording Step I Purchase Requisition Step I Sales Quotation Step II Purchase Order Step II Sales Order Step III Receiving Materials Step III Delivery of Materials Purchasing and Receiving Process Sales and Delivery Process

12 Basic Inventory Management Functions Recording Reporting Monitoring

13 Basic Inventory Management Functions Reports Receiving Report Summary Inventory Audit Inventory Status Delivery Summary Pull-out Summary

14 Basic Inventory Management Functions Reports

15 Basic Inventory Management Functions Reports

16 Basic Inventory Management Functions Reports

17 Basic Inventory Management Functions Recording Reporting Monitoring

18 Basic Inventory Management Monitoring Approvals Alerts Warning Blockings

19 Classification of Materials Establishing the identity of your items. A.) Grouping C.) Location -Use - Warehouse -Nature - Bin Location -Value B.) Coding D.) Picture -Barcode -Item Code -Business Partner Coding

20 Classification of Materials

21 Inventory Costing A.) Valuation Method B.) Inventory Cost

22 Inventory Costing A.) Valuation Method B.) Inventory Cost

23 Inventory Costing A.) Valuation Method FIFO Moving Average Standard Specific Identification by Serial/Batch

24 Inventory Costing A.) Valuation Method B.) Inventory Cost

25 Inventory Costing and I.M Terms B.) Inventory Cost Holding Cost - cost to carry an item in inventory for a length of time, usually a year Ordering Cost - costs of ordering and receiving inventory Shortage Cost - when demand exceeds supply

26 EOQ - The economic order quantity, commonly referred to as EOQ, seeks to find a balance between holding too much or too little inventory. Basic EOQ model Demand is known, constant, and independent Lead time is known and constant Order quantity received is instantaneous and complete No shortage is allowed

27 Inventory Level EOQ Inventory Order Cycle Order quantity, Q Demand rate Reorder point, R 0 Lead time Lead time Order placed Order receipt Order placed Order receipt Time

28 Major Inventory Systems A.) Fixed Order Quantity System B.) Periodic Review

29 Major Inventory Systems A.) Fixed Order Quantity System B.) Periodic Review

30 Major Inventory System A.) Fixed Order Quantity System Safety Stock/Last Bag System - Safety stock refers to an additional amount of stock carried over the normal stocking level requirements as a buffer against uncertainty.

31 Inventory level Major Inventory System Reorder point, R Q 0 LT Safety Stock Time LT

32 Two-Bin System - Two containers of inventory; reorder when the first is empty The two-bin inventory control method is mainly used for small or low value items.

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34 Min-Max inventory The Min-Max inventory control method helps you define how much inventory you should maintain for specific items.

35 Inventory level Min-Max inventory Max Q Min 0 LT Safety Stock Time LT

36 Inventory System A.) Fixed Order Quantity System B.) Periodic Review

37 Inventory System B.) Periodic Review J.I.T (Just In Time) Periodic System ABC Classification

38 JIT The Just In Time (JIT) method works to lessen the volume of inventory that a business has on hand. It is considered a risky technique because you only purchase inventory a few days before it is needed for distribution or sale so that the items arrive just in time for use.

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40 Periodic system (fixed-time-period) It is an inventory control method where orders are periodically placed, but the order quantity is different every time, and is also called Fixed Period Deficit Ordering System.

41 ABC Classification (Pareto Principle) Classification model Known as Always Better Control (ABC) based upon Pareto rule ( 80/20 rule)

42 ABC Classification (Pareto Principle) ABC ANALYSIS Divides inventory into three classes based on Consumption Value Consumption Value = (Unit price of an item) (No. of units consumed per annum) Class A - High Consumption Value Class B - Medium Consumption Value Class C - Low Consumption Value

43 ABC Classification (Pareto Principle) A Items

44 Conclusion Inventory control methods vary from company to company, commodity to commodity and SKU to SKU. The inventory control method that works best for slow-moving items might not work as well for fast-moving items. A company might have 1 million different SKUs and use only five different inventory control methods. One thing to remember there is no perfect method to manage inventory. Kenneth Hamlett, Methods for Inventory Control,

45 MRP-Materials Requirements Planning Material requirements planning (MRP) is a production planning, scheduling, and inventory control system used to manage manufacturing processes. Most MRP systems are software-based, while it is possible to conduct MRP by hand as well.

46 MRP-Materials Requirements Planning An MRP system is intended to simultaneously meet three objectives: Ensure materials are available for production and products are available for delivery to customers. Maintain the lowest possible material and product levels in store Plan manufacturing activities, delivery schedules and purchasing activities.

47 5 Simple Best Practices for Great Inventory Management Look for key features to evaluate systems that allow you to manage your company s inventory digitally. Web-based Mobile Inventory Barcode integration Unit of Measurement Conversion Data Import Batch Processes Cycle / Physical Counts Alerts and Notifications

48 Inventory control system should contain several key elements Every parts operation needs an inventory control system of some sort, which should incorporate the following key elements: It must warn parts personnel far in advance that a part is being depleted from stock. It must list a part s historical purchase price so that if the price changes, the manager will be able look into the issue and ascertain whether this change is a price increase or due to incorrect billing. It should list vendors that offer the best prices. It should give past usage rates so that the manager can determine proper inventory levels. It should require as little writing as possible, particularly by mechanics. John Dolce, 15 Tips for Improving Your Inventory Control,

49 Solutions & Recommendations

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51 The Solution: SAP Business One Sales!? Services A single system to streamline the entire business Instant and complete business information Finance Operations Strengthen customer relationship and loyalty Adaptable to your business and industry needs Executive Sales Operations Services Finance Customer A Single Integrated Solution SAP 2008 / Page 51

52 A Single System to Streamline Your Entire Business Integrate All Critical Business Functions Manage your entire business end-to-end across sales, customers, purchasing, inventory, operations, financials and HR functions, all in a single system Operations Executive Sales Services Eliminate Duplicates & Redundancies Information captured is instantly accessible in the entire system, eliminating redundant data entries and errors in different systems Finance Customer Proactively Focus on What s Important Workflow-based alerts to monitor, notify and trigger auto-responses when important business events occur SAP 2008 / Page 52

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54 Why manage your inventory? Customer Satisfaction Forecasting Controlling Cost Optimal Storage

55 How do we manage our Inventory? Establish the identity of your Items Identify Inventory Risks Facilitate basic inventory functions Implement mitigating controls

56 What are the risks in Inventory? Theft/Inventory Loss Inventory Waste Damage Shelf Life Life Cycle Other common problems

57 The Solution:

58 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Theft/Inventory Loss Stock Card, Random Count Serial/Batch Mangement & Inventory Count /Invntory Posting List

59 Setting Serial and Batch Numbers

60 Serial Number Transaction Report

61 Inventory Counting

62 Inventory Posting

63 Inventory Posting List

64 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Theft/Inventory Loss Inventory Waste Stock Card, Random Count J.I.T Serial/Batch Management & Inventory Count Procurement Confirmation Wizard

65 Procurement Process

66 Procurement Process

67 Procurement Process

68 Procurement Process

69 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management

70 Serial /Batch Management

71 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting

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73 Forecasting in SAP B1

74 Forecasting in SAP B1

75 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting Damage Basic Inventory Management function UoM Package Type/Approvals, Restrictions

76 UoM Package Types

77 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting Damage Over Delivery of Items or Stock -Outs Basic Inventory Management function Min Max Method UoM Package Type/Approvals, Restrictions Alert management, Blockings

78 Alert Management for Minimum/Maximum Stock

79 Minimum and Maximum Inventory per warehouse

80 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting Damage Over Delivery of Items and Stock-outs Surprise Purchase Orders Basic Inventory Management function Min Max Method Internal Communications/Forecasting UoM Package Type/Approvals, Restrictions Alert management, Blockings Approval Procedure/Blockings

81 Approval Procedures

82 Approval Procedures

83 Approval Procedures

84 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting Damage Over Delivery of Items and Stock outs Surprise Purchase Orders Having too many SKUs in too many places Basic Inventory Management function Min Max Method Internal Communications/Forecasting ABC Analysis UoM Package Type/Approvals, Restrictions Alert management, Blockings Approval Procedure/Blockings BIN Location Management

85 BIN Location

86 BIN Location

87 BIN Location

88 BIN Location and Barcode

89 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting Damage Over Delivery of Items or stock-outs Surprise Purchase Orders Having too many SKUs in too many places Performance Measurement are lacking Basic Inventory Management function Min Max Method Internal Communications/Forecasting ABC Analysis MRP UoM Package Type/Approvals, Restrictions Alert management, Blockings Approval Procedure/Blockings BIN Location Management MRP

90 Material Requirements Planning Overview Define Planning Data Run MRP View order recommendations

91 MRP Basics Input Output Sales Order / A/R Reserve Invoice Purchase Order / A/P Reserve Invoice Forecast Planning Data from Item Master Inventory Bill of Material Material Requirements Planning Parent Production Order Parent Dependant Requirement Production Order Purchase Purchase Order Order

92 MRP- Materials Requirements Planning

93 MRP- Materials Requirements Planning

94 MRP- Materials Requirements Planning

95 MRP- Materials Requirements Planning

96 MRP- Materials Requirements Planning

97 MRP- Materials Requirements Planning

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99 Item Master Data Planning data

100 Item Master Data Inventory Data

101 Purchases to supplier

102 Barcode in SAP B1

103 Multiple units of Measure

104 SAP Inventory Reports Inventory Posting List

105 SAP Inventory Reports Inventory Status

106 SAP Inventory Reports Inventory Status (Available to Promise)

107 SAP Inventory Reports Inventory in Warehouse Report

108 SAP Inventory Reports Inventory Audit Report

109 SAP Inventory Reports Batches and Serial Inventory Audit Report

110 SAP Inventory Reports Inventory Turnover Analysis

111 Common Inventory Problems/Risks and Control Measure RISK/problems Principle /Control measure SAP B1 SOLUTIONS Serial/Batch Management & Theft/Inventory Loss Stock Card, Random Count Inventory Count Procurement Confirmation Inventory Waste J.I.T Wizard Shelf Life FIFO Stock Movement plan Serial/Batch Management Life Cycle Fixed Order Quantity Forecasting Damage Over Delivery of Items and Stock-Outs Surprise Purchase Orders Having too many SKUs in too many places Performance Measurement are lacking Basic Inventory Management function Min Max Method Internal Communications/Forecasting ABC Analysis MRP UoM Package Type/Approvals, Restrictions Alert management, Blockings Approval Procedure/Blockings BIN Location Management MRP

112 SAP Business One Q & A