inventory record accuracy
DESCRIPTION
The POWER of CYCLE Counting, Inventory Record Accuracy (IRA). Mendeteksi Penyakit Working Capital MEMATIKAN BISNIS ANDA!TRANSCRIPT
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 1
of
Inventory Record Accuracy
@Mitratama, RODAMAS Group08 September 2011
+62 816 729 [email protected]
Partisipasi 100%
ACCURACYIs NOT
Always absolute.
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 2
WHAT are we GOING to MAKE?
WHAT does it take to MAKE?
WHAT do we HAVE?
WHAT do we HAVE to GET?
WHEN?Physical count within RANGE
=
Inventory Record Accuracy
An Accurate Record.
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 3
RECORD ACCURACY =
TOTAL accurate recordsX 100%TOTAL records checked
Cycle Counting Status:
No. Record Counting Tolerance Hit Miss
1 100 94 +2% X
2 100 95 +5% X
3 100 96 +2% X
4 100 98 +2% X
5 100 99 +2% X
InventoryRecordAccuracy5 100 99 +2% X
6 100 100 +2% X
7 100 103 +5% X
8 100 104 +5% X
9 100 105 +2% X
10 100 106 +5% X
TOTAL 1,000 1,000 6 4
y
= 6 / 10 = 60%
TOLERANCE?CLASS Quantity Value Tolerance
A 20 80 +0%
B 30 15 +2%
C 50 5 +5%
TOLERANCE?5%or
2%2%
Inventory Record AccuracyPROGRESS
100%
50%
40%
TIME
Inventory Record Accuracy Phase
100%
Phase #2: Develop Initial
Phase #3: Cycle Counting
50%
TIME
Phase #1: Design & Preparation
Balance
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 4
PHASE #1: Design & Preparation (1/7)
IN OUTON HAND( d)
+ ‐
DESIGN PROCESS TRANSACTION
(record)
PHASE #1: Design & Preparation (1/7)
IN OUTSTOCK(fi ik)
+ ‐
DESIGN PROCESS TRANSACTION
(fisik)
PHASE #1: Design & Preparation (1/7)
In transit RMOn handStock
WIP RM + FGS
DESIGN PROCESS TRANSACTION
WIP RM + FGSFGS
In transit FGSScrap + Losses
PHASE #1: Design & Preparation (2/7)
ADDRESS = PWF‐Sc01‐WIP
NegaraKota
DepartmentSection
P = ProductionW =WET
MEASURE STARTING POINT
Kode PosJalanGedung
Working StationRackKatagory
W WETF = FillingSc = SachetWIP
PHASE #1: Design & Preparation (2/7)
Address: PWF‐Sc01‐WIP
Description: ______________________________
Item No.: ______________________________
Unit: ______________________________QTY:
MEASURE STARTING POINT
QTY: ________________________________________________________________________
Ref. No.: ______________________________
Tanggal: Tanda Tangan:
PHASE #1: Design & Preparation (3/7)
PeopleSystem
PROVIDE TOOLS
SystemPhysical
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 5
PHASE #1: Design & Preparation (4/7)
PemetaanData per Area
Format
POLICY & PROCEDURE
FormatRekonsiliasi
Pelaporan
PHASE #1: Design & Preparation (4/7)
In TransitOn GoingWIP
POLICY & PROCEDURE
WIPRejectLosses
PHASE #1: Design & Preparation (5/7)
TRAINNING
PHASE #1: Design & Preparation (6/7)
CounterLeader on Area (PIC)
RekonsiliasiReporting
ASSIGN RESPONSIBILITIES
ReportingVerifikasi
Summary ClosingSign-off
PHASE #1: Design & Preparation (7/7)
CLASS Quantity Value Tolerance
A 20 80 +0%
B 30 15 +2%
C 50 5 +5%
IMPLEMENTATION
A = 100% Counted = WeeklyB = Random 50% Counted = Be‐WeeklyC = Random 50% Counted = Monthly
PHASE #2: Develop Initial balance
Purchase Sales
STOCK
+ ‐
+‐
WIP
TEORI, PERHITUNGAN, FISIK
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 6
PHASE #3: Cycle Counting (1/2)
Leader = AccountingPIC = SupervisorCounting = ???
CONTROL ‘TEAM’
Reporting = Admin FloorReconciliation = PPICClosing = Accounting
PHASE #3: Cycle Counting (2/2)
Authorized PersonCounted Twice
Clear Instruction
ON GOING PROGRAM
Man
h d M hi l
Measurement
IRA
Fishbone Diagram
Method Machine Materials
WIP ProductionOrder Receiving
Freq
uen
cy
Pareto Analysis
Order Receiving
Scrap
Type of Error
WIP
Freq
uen
cy Salah labelSalah transaksiSalah hitung
Pareto Analysis
Type of Error
gSalah lokasi
WIP
Freq
uen
cy Salah label• Training• Orang• Hilang
Pareto Analysis
Type of Error
• Hilang• Tercampur
TuLIPBerhasil "Cycle Counting"
Inventory Record Accuracy @WawangSukmoro 7
BOM AccuracyScrap Records
Pengantian MaterialsAlokasi pemakaianPelaporan Produksi
On Going Usage
Ketepatan Dokumentasi
g g
RECORD ACCURACY =
TOTAL accurate recordsX 100%TOTAL records checked
< 90% ~ Kurang90 < Cukup < 9596 < Baik < 97
Inventory Record Accuracy
97 < Puas < 9898 < EXCELLENCE!