1 © the delos partnership 2006 inventory accuracy how to get to 98 %
DESCRIPTION
3 © The Delos Partnership 2006 Steps to Gaining Inventory Accuracy 1.Establish definition of accuracy 2.Establish control group to identify causes of errors 3.Review material flows 4.Create Limited Access 5.Define systems and processes 6.Educate users 7.Train users 8.Cycle count 9.Eliminate annual physical 10.Never give up the challengeTRANSCRIPT
1 © The Delos Partnership 2006
Inventory AccuracyInventory Accuracy
How to get to 98 %
2 © The Delos Partnership 2006
Inventory AccuracyInventory Accuracy
• Vital to have 100 % accuracy of inventory:– In the stores– On the shop floor– Anywhere in the company
• Vital to have 100 % accuracy of work in process
3 © The Delos Partnership 2006
Steps to Gaining Inventory Steps to Gaining Inventory AccuracyAccuracy1. Establish definition of accuracy2. Establish control group to identify causes of
errors3. Review material flows4. Create Limited Access5. Define systems and processes6. Educate users7. Train users8. Cycle count9. Eliminate annual physical10. Never give up the challenge
4 © The Delos Partnership 2006
Establish definition of accuracyEstablish definition of accuracy
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How Accurate Is This How Accurate Is This Data ?Data ?
Item Counted Quantity
Value ( £’s) Computer Record
Value ( £’s)
12351 995 995 1000 100012352 996 996 1000 100012353 997 997 1000 100012357 998 998 1000 100012358 999 999 1000 100012359 1000 1000 1000 100012360 1001 1001 1000 100012372 1002 1002 1000 100012373 1003 1003 1000 100012374 1004 1004 1000 100012375 1005 1005 1000 1000TOTAL 11,000 £ 11,000 11,000 £ 11,000
6 © The Delos Partnership 2006
How Accurate Is This How Accurate Is This Data ?Data ?
Inventory status
Stores Location ST001
Factory F0001
Part Number 91121 200 Location ST001 200 Location F0001 0
Count 100
Count 100
7 © The Delos Partnership 2006
Definition of AccuracyDefinition of Accuracy
Number of correct counts
Number of items counted
Item = product by location
X 100 %
8 © The Delos Partnership 2006
Definition of Accuracy - Definition of Accuracy - TolerancesTolerancesCount is accurate if item is within preset
tolerance
Computer 100
Count 97 98 99 100 101 102 103
E.g. suppose tolerance = +/- 2 %
Accurate within these limits
9 © The Delos Partnership 2006
How Accurate Is This How Accurate Is This Data ?Data ?
Item Counted Quantity
Computer Record
Tolerance=/- %
Hit/Miss
12351 995 100012352 996 1000 +/-2 %12353 997 1000 +/-5 %12357 998 1000 +/-2 %12358 999 100012359 1000 100012360 1001 100012372 1002 1000 +/- 2 %12373 1003 100012374 1004 1000 +/-5 %12375 1005 1000TOTAL 11,000 11,000
10 © The Delos Partnership 2006
How Accurate Is This How Accurate Is This Data ?Data ?
Item Counted Quantity
Computer Record
Tolerance=/- %
Hit/Miss
12351 995 1000 Miss12352 996 1000 +/-2 % Miss12353 997 1000 +/-5% Hit12357 998 1000 +/-2 % Hit12358 999 1000 Miss12359 1000 1000 Hit12360 1001 1000 Miss12372 1002 1000 +/- 2 % Hit12373 1003 1000 Miss12374 1004 1000 +/-5 % Hit12375 1005 1000 MissTOTAL 11,000 11,000 =5/11 = 45 %
11 © The Delos Partnership 2006
2. Establish Control Group2. Establish Control Group
12 © The Delos Partnership 2006
2. Establish Control Group 2. Establish Control Group and start countingand start counting
1. Identify cycle counting resource2. Identify 100 parts to be regularly counted3. Establish counting regime4. Week 1 Count 20 each day
Reset computer to quantity counted5. Week 2 and on
Count same items as counted previous week on same day.
6. Investigate reasons for errors
13 © The Delos Partnership 2006
2. Establish Control Group2. Establish Control Group
1. Select 100 different items– Fast moving– Slow moving– Large– Little– Expensive– Trivial
2. Purpose of control group is to identify sources of error to all items
14 © The Delos Partnership 2006
Likely Causes of ErrorsLikely Causes of Errors
Inventory inaccurate
Equipment People Computer
Policies Procedures
Take the observed problems back To the root cause – 5 Why’s
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3. Review Material Flows3. Review Material Flows
Kitting area
Kittingarea
Production
Production
Production
Stores Stores or Work-in-Process ?
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44. Create Limited Access. Create Limited Access
Physical Limited access
Psychological limited access• Provide Terminals• Provide Training
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4. Create Limited Access4. Create Limited Access
Kitting area
Kittingarea
Production
Production
Production
Stores Stores or Work-in-Process ?
18 © The Delos Partnership 2006
55. Define Systems and . Define Systems and ProceduresProceduresEvery material movement needs a
transactionMaterial movement can be recorded by
discrete issue or backflush
In = +
Out = -
In = +
Out = -
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Discrete IssueDiscrete Issue
1. Release order : allocate materials2. Paperwork received in stores3. Items picked4. Issued to factory etc.5. On hand balance downdated
Stage Allocated On Hand Available
Step 1 0 100 100
Step 2 100 100 0
Step 3 100 100 0
Step 4 100 100 0
Step 5 0 0 0
20 © The Delos Partnership 2006
Generating the Pick ListGenerating the Pick Listfrom the Bill of Materialfrom the Bill of Material
Location PartNumber
Description Qty Req’d
QtyIssued
Point of Use
A114 43768 Pen Barrel 20 SA
A118 76452 Finished Nib 20 SA
M054 89563 Cap 20 SA
Work Order Number : 4567 Quantity : 100 Part Number : 14356 Start : 1/07/02 Description : Pen Complete : 15/07/02
21 © The Delos Partnership 2006
Generating the Pick ListGenerating the Pick Listfrom the Bill of Materialfrom the Bill of Material
Location PartNumber
Description Qty Req’d
QtyIssued
Point of Use
A114 43768 Pen Barrel 20 20 SA
A118 76452 Finished Nib 20 20 SA
M054 89563 Cap 20 20 SA
Work Order Number : 4567 Quantity : 100 Part Number : 14356 Start : 1/07/02 Description : Pen Complete : 15/07/02
22 © The Delos Partnership 2006
Backflush Technique Backflush Technique
• Backflushing is a technique for downdating inventory
• Uses Bill of Material to work out what has been used
• Supports an environment in which works orders are not used
• Allows bulk replenishment• Simplifies material control
23 © The Delos Partnership 2006
Backflush MechanicsBackflush Mechanics
Red PenPart Number 14356
Pen BarrelPart Number 43768
Finished NibPart Number 76452
CapPart Number 89563
Stock record for Cap 89563 – works order number 4675
Stores on hand
Transaction Factory On Hand
Total Stock
1000 Opening Balance 1000
800 Move 200 1000
800 Complete ProductionOf 14356
0 800
24 © The Delos Partnership 2006
Backflushing Backflushing PrerequisitesPrerequisites
Timing of transactions Report Production in Timely manner Scrap/Yield/Exception reporting needs to be
done quickly Bill of material accuracy needs to be 100 % Point of Use Inventory Accuracy needs to be
> 95 % Routings need to be 100 % accurate Bill of Material change control needs to be
excellent
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66. Educate Users. Educate Users Educate all users
Sales and Marketing Production Planning Supervision Research and Development
Ensure understanding of Importance Continue to educate Provide training to users of system
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77. Train Users. Train Users
• Ensure they understand• transactions• Ensure they understand • procedures• Ensure they carry out transactions accurately and in a timely
fashion
27 © The Delos Partnership 2006
88. Carry out cycle counting. Carry out cycle counting
Three recognised ways to cycle countBy part number
1. Random selection of parts2. ABC Cycle Count
By Location
Product Class
% of Volume
% of Value % Tolerance
Counts per annum
Interval- weeks
“A” Class 20 % 80 % +/- 0% 4 13
“B” Class 30 % 15 % +/- 2% 2 26
“C” Class 50 % 5% +/- 5% 1 52
28 © The Delos Partnership 2006
Process for getting Data Process for getting Data RightRight
0
20
40
60
80
100
120
1 2 3 4 5 6 7 8 9 10 11 12
Accuracy
Control Group
Audit
Fix Data Base
Control Group
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Process Control cycle Process Control cycle countingcounting
Divide Warehouse into locations For cycle counting
Week 1 Week 2 Week 3 Week 4 Week 5`
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Process ControlProcess Control
Counting regime :When Easy to count
– Low balance high exposureObvious errors
– Eyeball large quantitiesBy Location
– Efficient– All physical inventory– Ensures physical locations recognised– Reconciliation easier
31 © The Delos Partnership 2006
Process Control cycle Process Control cycle countingcounting
Location Part Quantity Count Hit/Number Miss
A3452 23654 100 100 HitA3453 24568 1245
A3454 24367 22 20 MissA3455 70659 2,234
A3456 39060 101 101 HitA3457 39081 43 43 Hit
A3458 42020 75 75 Hit4 hits5 counts
= 90 %
32 © The Delos Partnership 2006
99. Do away with the annual . Do away with the annual PhysicalPhysicalEstablish 98 % accuracy through Cycle
countingShow regular resultsProcess under control so need for once a year
check of “everything”
No auditors here thanks
33 © The Delos Partnership 2006
10. Never Give up10. Never Give up
• Continue with Control Group
• Continue with Process control cycle counting forever– Informal disciplines will creep back