Efficient Inventory and Warehouse Management Strategies
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Learn about optimal inventory storage, retrieval systems, stock location methods, and the impact of inaccurate inventory records on operations. Discover key strategies and systems for successful warehouse management.
Efficient Inventory and Warehouse Management Strategies
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Chapter 12 實體存貨與倉儲管理 (physical inventory and warehouse management)
倉儲管理目標 • 倉儲的目標: 最少成本與最佳顧客服務 • 有效率的倉儲作業必須: • Provide timely customer service • Keep track of items so they can be found readily and correctly • Minimize the total physical effort and thus the cost of moving goods into and out of storage • Provide communication links w/ customers
倉儲活動 • Receive goods • ID the goods • Dispatch the goods to storage • Hold goods • Pick goods • Marshal the shipment • Dispatch the shipment • Operate an information system
空間利用率與易取得性cube utilization and accessibility • 易取得性: be able to get goods wanted with a minimum amount of work • 空間利用率: the use of space horizontally and vertically • Fig. 12.2
庫存位置 stock location (warehouse layout) • Concerns w/ the location of individual items in the warehouse • No single universal stock location system suitable for the all occasions • Which system, or mix of systems, depends on the type of goods stored, the type of storage facilities needed, the throughput, and the size of orders
庫存位置系統 • Group functionally related items together • Group fasting-moving items together • Group physically similar items together • Locate working stock and reserve stock separately
固定位置系統 • An SKU is assigned a permanent location or locations, and no other items are stored there • Store and retrieve items w/ minimum of record keeping • Used in small warehouse where space is not at premium, where throughput is small, and where there are a few SKUs • Adv.: everything is nice and simple so things are readily found • Disadv.: have poor cube utilization – on the average, only 50% of cube space is utilized (presume the avg inv is half the order qty)
浮動位置系統 • Goods are stored wherever there is appropriate space for them • The same SKU may be stored in several locations at the same time and different locations at different times • Adv.: Improved cube utilization－Modern warehouses are usually computer based • Disadv.: Need accurate and up-to-date info on item location and the availability of empty storage space so items can be put away and retrieved efficiently
使用點儲存(point-of-use storage) • Inventory is stored close to where it will be used －particularly in repetitive mfg and in a JIT environment • Adv.: • mat’ls are readily accessible to users • Mat’l handling is reduced or eliminated • Central storage costs are reduced • Mat’l is accessible at all times
中央儲存 • Contains all inventory in one central location • Adv.: • Ease of control • Inv record accuracy is easier to maintain • Specialized storage can be used • Reduced safety stocks, since users do not need to carry their own safety stock
訂單揀貨系統 • Area system: • Circulates throughout the warehouse selecting the items on the order ,much as a shopper would in a supermarket • Generally used in small warehouse where goods are stored in fixed locations
訂單揀貨系統 • Zone system: • The warehouse is broken into zones, and order pickers work only in their own area • Each order is handled separately and leaves the zone b/f another is handled • Zones are usually established by grouping related parts together
訂單揀貨系統 • Multi-order system: • A number of orders are gathered together and all the items divided by zone • Pickers then circulate through their area, collecting all the items required for that group of orders • Suitable for situations where there are many items or many small orders w/ few items
交易步驟 • ID the item • Verify quantity • Record the transaction • Physically execute the transaction
不準確的存貨記錄後果 • Lost sales • Shortage and disrupted schedules • Excess inventory (of the wrong things) • Low productivity • Poor delivery performance • Excessive expediting, since people will always be reacting to a bad situation rather than planning for the future
不準確存貨記錄的原因 • Unauthorized withdrawal of mat’l • Unsecured stockroom • Poorly trained personnel • Inaccurate transaction recording • Poor transaction recording system • Lack of audit capability
量測存貨記錄的準確性 • Accuracy is 100% or 20% or something else? (2 of 10 items are correct)
允差 tolerance • The amount of permissible variation b/w an inv record and a physical count • To judge inv accuracy • Set on individual items based on value, critical nature of the item, availability, lead time, ability to stop production, safety problems, or the difficulty of getting precise measurement • Fig. 12.4
稽核存貨準確性的目標 • To audit record accuracy • Find the causes of record inaccuracy and eliminate them
Two basic methods of checking the accuracy of inv records • Periodic (usually annual) counts of all items • To satisfy the financial auditors that the inv records represent the value of the inv • To planners, the physical inv represents an opportunity to correct any inaccuracies in the records • Cyclic (usually daily) counts of specified items －does 稽核存貨準確性的目標
Periodic (annual) inventory • Three factors in good preparation: • Housekeeping • Inv. Must be sorted and the same parts collected together so they can be counted • Identification • Parts must be clearly identified and tagged w/ part number • Training • Those who are going to do the inv must be properly instructed and trained in taking inv.
盤點步驟 • Count items and record the count on a ticket left on the item • Verify this count by recounting or by sampling • When the verification is finished, collect the tickets and list the items in each department • Reconcile the inv. Records for differences b/w the physical count and inv. dollars
Problems of taking an annual physical inv. • Usually the factory has to be shut down, thus losing production; labor and paperwork are expensive; job is often done hurriedly and poorly since there is much pressure to get it done • People doing the inv. are not used to the job and are prone to making errors
循環盤點 cycle counting • A system of counting inv. continually throughout the year • Counts are scheduled so that each item is counted on a predetermined schedule • Adv. • Timely detection and correction of problems • Complete or partial reduction of lost production • Use of personnel trained and dedicated to cycle counting
Count frequency • The number of times an item is counted in a year • Basic idea is to count some items each day so all items are counted a predetermined number of times each year • the count frequency should increase as the value of the item and number of transactions (chance of error) increase
When to count • An order is placed • An order is retrieved • The inv. Record reaches zero • A specified number of transactions have occurred • An error occurs
物料堆放方法及料架種類 • 物料堆放方法 • 平面堆放方式 • 立體堆放方式 • 鉤式堆放 • 料架的種類 • 金屬製料架 • 木製料架 • 塑膠製料架
