part iii information for inventory management
TRANSCRIPT
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Part III
Information for
Inventory Management
Chapter 6
Sources of Information
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Aims of the Chapter
After reading this chapter you should be able to do the following:
• discuss the information needed for inventory management;
• outline the design of an inventory management information
system;
• consider the information supplied by accounting;
• do an ABC analysis of stock;
• describe the function of procurement and its role in inventory
management;
• outline the impact of e-commerce;
• discuss the role of warehousing;
• describe important factors in the design of a warehouse.
Inventory Management Information
Systems: Types of Information
Inventory managers need a huge amount of information:
• the items, their specification and use,
• business plans and strategies,
• suppliers, customers,
• promotions, storage requirements, constraints,
• prevailing conditions of trade, contract law,
• transport arrangements, competitors,
• Business environment, changing conditions,
• international trade, special requirements, and so on.
This information is collected from many sources, and is
presented by the organization’s management information
system (MIS).
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Inventory Management Information
Systems (MIS)
• The MIS controls the flow of information throughout an
organization, and makes sure that everyone has the information
they need to work properly.
• It collects, checks, organizes, stores, analyses and presents
information in the most appropriate formats to everyone who
needs it.
• Sometimes it is convenient to refer to an inventory management
information system which consists of all the parts of an MIS that
are specifically concerned with inventory management.
• This collects information from both within the organization and
from external sources and presents it to inventory managers.
Inventory Management Information
Systems: Types of Information
• Business environment, which gives the overall context for
stocks: the state of competition, changing circumstances,
likely shortages or supply difficulties, state of the economy,
government policies and legislation, inflation, exchange
rates, tariffs, duties, taxes and quotas, and a range of other
external factors that might affect stocks.
• Organizational strategies, which are the internal policies that
show what the organization is doing in the long term and the
support needed from inventory management: details of
objectives, planned operations and products, priorities,
financing arrangements, trading relationship, and a range of
other internal factors that might affect stocks.
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Inventory Management Information
Systems: Types of Information
• Performance targets, which identify the factors that are
important to the organization – and consequently to
inventory management – and the levels of performance to be
achieved: aims for customer service, productivity, stock
turnover, return on inventory investment, overall investment
in stock, improvements, balance between competing
objectives, etc.
• Plans for operations and production. material requirements,
new products, changes to existing products, promotions,
size of demands, etc.
Inventory Management Information
Systems: Types of Information
• Costs. Our independent demand inventory models are based
on reliable figures for the four cost components of unit,
reordering, holding and shortage. Managers need detailed
breakdowns of other relevant costs, such as opportunity
costs, financial charges, transport, storage, packaging,
handling, insurance, obsolescence, internal movement,
delays, distribution, etc.
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Inventory Management Information
Systems: Types of Information
• Customer information. Inventory managers pass materials to
customers (either internal or external). alliances, trading
arrangements, identification of existing and new customers,
contact details, salespeople used, locations, products
demanded, size of orders, regular orders, preferred delivery
modes, purchases from competitors, sensitivity to prices,
returns, complaints, attitude towards shortages, back-orders,
service level and lead times demanded, stocks held,
purchasing system used, attitudes towards shared systems
and integration, trading history, payment method, financial
security, credit terms requested, etc.
Inventory Management Information
Systems: Types of Information
• Demand patterns. To have enough stock to meet likely patterns of
future demand, we need forecasts for each period, complete
histories of past demand, changing patterns over time, reasons
for changes, amount of variation and uncertainty, factors that
affect demand, special promotions and marketing campaigns,
regular orders, advance sales, etc.
• Supplier information, which gives all relevant information about
the supply of materials, including preferred suppliers, alliances
and other trading arrangements, attitude towards shared systems
and integration, locations, products supplied, quality, purchasing
system used, lead times, reliability, trading history, financial
security, alternative suppliers, process and purchase conditions,
credit terms offered, attitude towards returns, payment method,
etc.
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Inventory Management Information
Systems: Types of Information
• Product details, which identify the exact item and include
identification codes, description, design features and
specifications, limitations, unit prices, discounts available,
special conditions for storage or supply, quality available,
weight and size, packaging, available suppliers, order
restrictions, relative make/buy costs, and alternative
products.
• Warehousing information, which shows where stocks are
held, including locations, stock levels in each location, space
available, facilities and conditions, material handling
equipment, security, ownership, restricted access, costs and
performance.
Inventory Management Information
Systems: Types of Information
• Transport, including the types of transport available, types of
vehicle, special requirements and facilities, access, speed of
delivery, scheduled services and frequency, reliability, costs,
capacities, back-hauls and reverse logistics.
• Stock information. This gives the details of all current stocks
held: identification codes, current holdings, locations,
inventory policies, reorder levels and quantities, deliveries
due, suppliers, quality, costs, units reserved for known
orders, allowed variation in stock, maximum and minimum
levels, age of units, obsolescent and slow moving items,
insurance, special conditions, allocation of stocks to orders,
back-orders, etc.
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Inventory Management Information
Systems: Types of Information
• Orders outstanding, which are all the orders with deliveries
expected in the near future, details of materials in transit
(coming from suppliers, going to customers, or moving
between facilities), routes, transport operators, current
locations, quantities, due dates, reliability, special handling
required, potential difficulties, back-orders, urgent deliveries,
etc.
Inventory Management Information
Systems: Types of Information
• Orders outstanding, which are all the orders with deliveries
expected in the near future, details of materials in transit
(coming from suppliers, going to customers, or moving
between facilities), routes, transport operators, current
locations, quantities, due dates, reliability, special handling
required, potential difficulties, back-orders, urgent deliveries,
etc.
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Inventory Management Information
Systems: Types of Information
Inventory Management Information
Systems: Transaction Recording
• Inventory MIS has to track every detail of stock movement,
from orders sent to suppliers, through to payments received,
for finished products delivered to customers.
• A typical transaction recording system might do the
following:
– maintain accurate records of current stocks, customers,
suppliers, etc.;
– update these records after each order, delivery,
withdrawal or other transaction;
– check and validate all data used by the system.
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Inventory Management Information
Systems: Transaction Recording
Inventory Management Information
Systems: Transaction Recording
The information can be passed to the inventory control system,
for example, to do the following:• calculate variables, including forecasts of demand and lead time,
reorder levels, order quantities, costs, etc.;
• prepare and transmit orders when stocks fall to reorder levels;
• monitor order progress, with follow-up and expediting of overdue
orders;
• check orders, credit and payment facilities of customers;
• check deliveries, clear of invoices from suppliers and arrange
payment;
• report exceptional circumstances that need management attention;
• summarize data in management reports;
• update all parameters used by the system.
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Inventory Management Information
Systems: Transaction Recording
• The information flow through an organization is usually
separated from the material flow.
• The two are obviously connected, but managers have to
control operations and check that the transactions reported
actually happen.
• One facet of these checks are periodic, manual counts of
stock – called stocktaking – to find differences between
recorded and actual stock levels.
Inventory Management Information
Systems: Transaction Recording
There are several reasons why actual stock may differ from
recorded stock:• records may not have been updated with recent transactions;
• stock is mislaid (particularly when an item is kept in several
locations) and will turn up later;
• emergency or hurried withdrawals from stock may incur errors or
not be recorded;
• deliveries or withdrawals are recorded more than once by mistake;
• cancelled orders or withdrawals are not recorded;
• poor quality and returned items (either from customers or to
suppliers) are not recorded;
• stock become obsolete and is discarded;
• stock is stolen, damaged or deteriorates while in store.
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Inventory Management Information
Systems: Transaction Recording
• There are several ways of encouraging this, and perhaps the most
important is to restrict access to stores.
• Since stocktaking is an expensive and inconvenient, some only do
one check at the end of the financial year.
• A more useful approach uses cycle-counting, where stock is
checked at regular intervals. Typically, a small proportion of items
is checked every week, with high usage items checked every
month and less widely used items every three months.
• Checks may be triggered by specific conditions such as a reported
discrepancy in stock, an item with zero or low stock, an item with
very high stock, a back-order placed for an item that is recorded as
being in stock, or a period with no recorded demand.
• One common suggestion is that important items should have
discrepancies of less than 0.2% in stock levels, others 1%.
Information from Accounting
• Accountants supply data about the four cost components –
unit, reorder, holding and shortage costs.
• They also provide more detailed costs information and a lot of
transactional data. This information appears in records of
individual transactions, and is also summarized in the
organization’s accounts.
• 𝐺𝑟𝑜𝑠𝑠 𝑝𝑟𝑜fi𝑡 = 𝑛𝑒𝑡 𝑠𝑎𝑙𝑒𝑠 𝑟𝑒𝑣𝑒𝑛𝑢𝑒 − 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑠𝑜𝑙𝑑• 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑠𝑜𝑙𝑑 = 𝑜𝑝𝑒𝑛𝑖𝑛𝑔 𝑠𝑡𝑜𝑐𝑘 + 𝑛𝑒𝑡 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑠 −
𝑐𝑙𝑜𝑠𝑖𝑛𝑔 𝑠𝑡𝑜𝑐𝑘
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Information from Accounting
Opening stock £ 2,500.00 Sales £ 22,100.00
Purchases £ 13,000.00 less returns £ 600.00
Less returns £ 500.00 Net sales £ 21,500.00
Net purchases £ 12,500.00
Total stock £ 15,000.00
Less closing stock £ 3,000.00
Cost of products sold £ 12,000.00
Gross Profit £ 9,500.00
£ 21,500.00 £ 21,500.00
Information from Accounting
Raw materalsOpening stock of raw materials $ 60,000 Purchase $ 225,000
returns and allowances $ 10,500 purchase discount $ 4,500 $ 15,000
Net purchase $ 210,000 Inward transport $ 15,000 Cost of material purchased $ 225,000 Cost of material available $ 285,000 Closing stock of raw materials $ 105,000 Cost of raw material used $ 180,000
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Information from Accounting
Work in progressRaw materals used $ 180,000 Staff $ 390,000 Overheads $ 125,000 Total cost of operations $ 695,000 Opening stock of work in progress $ 45,000 Total work in progress $ 740,000 Closing stock of work in progress $ 75,000 Total cost of production $ 665,000
Finished goodsOpening stock of finished goods $ 135,000 Cost of production $ 665,000 Products available for sale $ 800,000 Closing stock of finished goods $ 180,000 Total cost of products sold $ 620,000
Information from Accounting:
Value of Stock
• An obvious problem with accounting information is that it
depends on the conventions used.
• The usual practice is to value stock at the lesser of unit cost
or realizable value.
• 𝑉𝑎𝑙𝑢𝑒 𝑜𝑓 𝑠𝑡𝑜𝑐𝑘 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 𝑖𝑛 𝑠𝑡𝑜𝑐𝑘 × 𝑢𝑛𝑖𝑡 𝑣𝑎𝑙𝑢𝑒– We can avoid the problem of variable stock levels by counting the
number of units held at a specific time, usually the end of the
financial year.
– If there are enough items in the stock, this gives a
reasonable overall average (providing the demands for
items are more or less independent, and do not all follow
the same strongly seasonal variation).
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Information from Accounting:
Value of Stock
• The other problem is variable unit cost.
• There are four main options for dealing with this:– Actual cost identifies each unit in stock with the price actually
paid for it.
– First-In-First-Out (FIFO) This assumes that the first units
arriving in stock are the first sold, so the value of remaining
stock is set by the amount paid for the last units bought.
– Last-In-First-Out (LIFO) assumes that the latest units added to
stock are used first, so the value of remaining stock is set by the
amount paid for the earliest units bought.
– Weighted average cost finds the average unit cost over a typical
period from: 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑐𝑜𝑠𝑡 =𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 𝑏𝑜𝑢𝑔ℎ𝑡
Information from Accounting:
Value of Stock
• The method chosen should give the fairest match of costs to
revenues.
• FIFO is the most widely used method, while LIFO is often
expressly prohibited, especially when it would artificially
reduce tax liabilities.
• Another consideration is that accounting conventions should
be consistent, so that organizations should not look for a
short-term gain by changing the basis of calculations.
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Worked Example #1
During her first job on a graduate trainee scheme, Madeleine Fraser
was given the following record of transactions for an item and asked
for her views on the profit. What answer could she give?
Date Purchases
number
Unit cost
(€)
Sales
number
Unit price
(€)
Opening stock 80 20
January 20 30
February 40 40
March 60 30
April 50 50
May 80 40
June 20 60
Worked Example #1
DatePurchases
numberUnit cost
SalesUnit price Inventory
Stock Value
(FIFO)
Stock Value
(LIFO)
Stock Value
(Wt. Avg.)number
Opening stock 80 € 20.00 80 € 1,600.00 € 1,600.00
January 20 € 30.00 60 € 1,200.00 € 1,200.00
February 40 € 40.00 20 € 400.00 € 400.00
March 60 € 30.00 80 € 2,200.00 € 2,200.00
April 50 € 50.00 30 € 900.00 € 700.00
May 80 € 40.00 110 € 4,100.00 € 3,900.00
June 20 € 60.00 90 € 3,500.00 € 3,100.00 € 2,700.00
Total 220 130
Total Cost € 6,600.00
Wt. Avg. € 30.00
Revenue € 5,900.00
Cost of products € 3,100.00 € 3,500.00 € 3,900.00
Gross Profit € 2,800.00 € 2,400.00 € 2,000.00
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Information from Accounting:
Value of Stock
• It is often expensive, difficult or impossible to count the actual
number of units in stock.
• We can estimate the value of stock without actually counting it,
by using the gross profit as a percentage of sales.
• If we assume this remains constant from one period to the next,
we can work backwards to estimate the value of closing stocks.
• There are variations on this approach for estimating the value of
closing stock, but they all rely on conventions and assumptions
and are clearly less reliable than methods based on actual stock
counts.
Information from Accounting:
Value of Stock
• It is often expensive, difficult or impossible to count the actual
number of units in stock.
• We can estimate the value of stock without actually counting it,
by using the gross profit as a percentage of sales.
• If we assume this remains constant from one period to the next,
we can work backwards to estimate the value of closing stocks.
• There are variations on this approach for estimating the value of
closing stock, but they all rely on conventions and assumptions
and are clearly less reliable than methods based on actual stock
counts.
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Worked Example #2
Last year PiHo Industries made a gross profit of 30% of sales. This
year they know that the opening stock of an item was $8,000 with
purchases of $22,000. If sales of the item were $40,000, what is the
value of closing stock?
Estimated closing stock = 30,000 – 28,000 = $2,000
Sales $ 40,000
Cost of products sold:
Opening stock $ 8,000
Purchases $ 22,000
Cost of products available $ 30,000
Estimated closing stock ???
Total cost of products sold $ 28,000
Gross Profit $ 12,000
Information from Accounting:
ABC Analysis of Stocks
• The origin of the ABC analysis ( Pareto analysis, or the ‘rule of
80–20’) came in the nineteenth century when Vilfredo Pareto
found that 20% of the population owned 80% of the wealth.
• In inventory control terms it means that 20% of the inventory
items need 80% of the attention, while the remaining 80% of
items need 20% of the attention.
• In particular, ABC analyses define the following:– A items are the few most expensive ones that need special
care.
– B items are ordinary ones that need standard care.
– C items are the large number of cheap items that need little
care.
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Information from Accounting:
ABC Analysis of Stocks
• Typically an organization might use an automated system to deal
with all B items.
• A items are more important, and although the automated system
might make some suggestions, managers make the final decisions
after a thorough review of circumstances.
• C items are very cheap and are usually left out of the automatic
system, to be dealt with by ad hoc procedures.
• An ABC analysis starts by taking each item and multiplying the
number of units used in a year by the unit cost.
• This gives the total annual use of items in terms of value.
• Usually, a few expensive items account for a lot of use, while many
cheap ones account for little use.
• If we list the items in order of decreasing annual use by value, A
items are at the top of the list and C items are at the bottom.
Information from Accounting:
ABC Analysis of Stocks
• Because an item is cheap or has low demand, it does not mean
that it is not important.
• organizations need stocks of all items – including those that are
cheap or not often used – to continue their smooth operations.
• They typically hold C items in stock because they:
– are more important than their classification suggests – like
spare parts;
– allow continued sales of an old item – which may no longer be
made;
– Are associated with sales of some A items;
– give high profits in relation to their low costs;
– are new items – which have not yet established a history of use;
– are expected by customers – like ink cartridges for old printers.
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Information from Accounting:
ABC Analysis of Stocks
• If the three categories are not descriptive enough, managers might
add extra ones.
• A fourth category is sometimes used, where D items are used so
infrequently they are ‘dead’ and are being considered for
withdrawal.
• And sometimes a special category is used for important spare
parts or other items that have a combination of high importance
and low use.
Information from Accounting:
ABC Analysis of Stocks
Category % of items Cum. % % of use Cum.%
A 10 10 70 70
B 20 30 20 90
C 70 100 10 100
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Worked Example #3
A small store with 10 categories of item has the following costs and
annual demands:
Do an ABC analysis of these items. How might stocks of each
category be controlled?
Item X1 Y7 W4 X2 X3 Y9 W5 Z3 Z4 X4
Unit Cost 3 2 3 8 2 10 1 5 20 4
Weekly demand 2 25 1 30 10 10 5 2 1 3
Item X2 Y9 Y7 X3 Z4 X4 Z3 X1 W5 W4
Cum. Item # 1 2 3 4 5 6 7 8 9 10
Cum. Item % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Unit Cost 8 10 2 2 20 4 5 3 1 3
Weekly demand 30 10 25 10 1 3 2 2 5 1
Weekly use 240 100 50 20 20 12 10 6 5 3
Cum. Use 240 340 390 410 430 442 452 458 463 466
Cum. Use in % 52% 73% 84% 88% 92% 95% 97% 98% 99% 100%
Category A B B C C C C C C C
Information about Supply and Demand:
Demand Forecasting
• The pattern of demand is perhaps the most important single factor
for inventory management.
• In general, there are two sources for demand data.
• For the first, an organization supplies products directly to
customers and has historical sales figures that it can use to
forecast future demand. (Chapter 7)
• For the second, an organization supplies materials to support
internal operations and can use the planned operations to give a
timetable for demands. (Chapters 8 and 9).
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Information about Supply and Demand:
Supply and Procurement
• Procurement is responsible for acquiring all the materials needed
by an organization.
• It consists of all the related activities needed to get materials,
services and any other materials from suppliers into an
organization.
• The overall aim of procurement is to guarantee a reliable supply of
materials to an organization.
Information about Supply and Demand:
Supply and Procurement
– working closely with user departments, developing relationships and
understanding their needs;
– finding good suppliers, working closely with them and developing
beneficial relationships;
– buying the right materials and making sure that they have acceptable
quality,
– arrive at the time and place needed, and meet any other requirements;
– negotiating good prices and conditions;
– keeping stocks low, considering inventory policies, investment,
standard and readily available materials, etc.;
– moving materials quickly through the supply chain, expediting
deliveries when necessary;
– keeping abreast of conditions, including pending price rises, scarcities,
new products, etc.
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Worked Example #2
Last year Lavender Spartak Limited had total sales of $216 million.
Their direct costs were $116 million for materials, $54 million for
employees and $24 million for overheads. What is the effect of
reducing the cost of materials by 1%?
in Millions$ Original Cost reduced by 1% Change
Total sales $ 216.00 $ 216.00
Direct cost $ 116.00 $ 114.84 -1.00%
Employees $ 54.00 $ 54.00
Overhead $ 24.00 $ 24.00
Total cost $ 194.00 $ 192.84
Gross profit $ 22.00 $ 23.16 5.27%
Information about Supply and Demand:
Procedure for Procurement
• Procurement looks for two factors: materials that satisfy their
requirements; and a supplier who can guarantee to deliver
the agreed materials.
• A useful approach for choosing the best supplier has the
following steps.– Look for alternative suppliers and build a long list of qualified
suppliers who can deliver the materials.
– Compare organizations on this long list and eliminate those who
are, for any reason, less desirable. Continue eliminating
organizations until you have a shortlist of four or five of the most
promising suppliers.
– Prepare an enquiry, or request for quotation, and send it to the
shortlist.
• ž Collect the bids returned by the shortlist, do a preliminary
evaluation, and
• eliminate those with major problems.
• ž Do a technical evaluation to see if the materials meet all
specifications.
• ž Do a commercial evaluation to compare the costs and other
conditions.
• ž Arrange a pre-award meeting to discuss bids with the
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Information about Supply and Demand:
Procedure for Procurement
– Collect the bids returned by the shortlist, do a preliminary
evaluation, and eliminate those with major problems.
– Do a technical evaluation to see if the materials meet all
specifications.
– Do a commercial evaluation to compare the costs and other
conditions.
– Arrange a pre-award meeting to discuss bids with the remaining
suppliers.
– At this point you should have enough information to make a
final choice of supplier, so arrange a pre-commitment meeting
to sort-out any last minute details.
– Award orders to the preferred supplier.
Information about Supply and Demand:
Procedure for Procurement
• This procedure should give a supplier who is financially secure,
with good long-term prospects, can supply the necessary
materials, guarantees quality, is reliable, has short lead times,
quotes reasonable prices and finance arrangements, is
responsive to customers’ needs, has necessary the skills and
experience, has a good reputation, uses convenient
procurement systems – and probably has many more enviable
qualities.
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Information about Supply and Demand:
Structure of a Purchasing Cycle
Information about Supply and Demand:
Information Flows for Order Processing
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Information about Supply and Demand:
e-Procurement
Changing patterns of procurement,
• Supply chains getting shorter,
• More customers use the Web,
• Alliances are reducing the number of suppliers used by each
organization,
• Amounts purchased are increasing as companies focus on their
core activities and outsource more, and
• Customers are demanding more from products and conditions of
purchase.
• e-procurement. – Surveys (see, Cummings, 2002) suggest that over 60% of UK
companies were using e-procurement by 2002– 57% of corporate buyers have purchased goods online, and 37%
percent expect to increase the amount of their budget spent online
http://www.acquitygroup.com/News-And-Ideas/News/Study-Finds-More-Than-1-3-of-Corporate-
Buyers-Expe#sthash.n2DgDYSe.dpuf
Information about Supply and Demand:
Advantages of e-Procurement
• allowing instant access to suppliers anywhere in the world;
• creating a transparent market where product details are
readily available and easily compared;
• Allowing comparison of standard terms of trade and rapid
negotiation of details;
• automating procurement with standard procedures;
• greatly reducing the time needed for transactions;
• reducing costs, typically by 12–15%;
• allowing outsourcing of some procurement activities to
suppliers or third parties;
• integrating seamlessly with suppliers’ information systems.
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Warehousing:
Purpose of Warehouses
• A warehouse is any place for storing materials. – Different terms: distribution centres and logistics centres.
• Inventory management is the management function
associated with decisions about stock, while warehousing is
the operational function that physically looks after it.
• Main aims of a warehouse:– providing necessary storage at key points in a supply chain,
– giving secure storage of the type needed by materials,
– keeping materials in good condition with little damage or loss,
– having low costs with high productivity and utilization of
resources, and giving safe working conditions.
Warehousing:
Warehousing Activities
• receiving materials from upstream suppliers;
• identifying the materials delivered, matching them to orders
and finding their intended user;• unloading materials from delivery vehicles;
• doing necessary checks on quantity, quality and condition;
• labelling materials (usually with bar codes or magnetic stripes) so
they can be identified and monitored;
• sorting materials as needed;
• moving materials to a bulk storage area;
• holding them in stock until needed;
• when necessary, moving materials from bulk storage to a smaller
picking store;
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Warehousing:
Warehousing Activities
• picking materials from this store to meet orders;
• moving the materials to a marshalling area;
• assembling materials into orders;
• packing and packaging as necessary;
• loading delivery vehicles and dispatching the order;
• controlling all communications and related systems, such as
inventory control and finance.
Warehousing:
New Warehousing Activities
Consolidating:
• Warehouses are places where small loads from different suppliers are
combined to give full vehicle loads for delivery to customers.
• This is the basis of postponement, where the final steps of production
are left to the last possible moment.
Bulk-breaking:
• Here a supplier sends all the demand for a particular area in a single
delivery to a local warehouse. The warehouse breaks this delivery into
the separate orders and passes them on to each customer.
Cross-docking
• The arrival of materials at a warehouse is coordinated with its
departures to customers, so that they are transferred directly from the
arrival area to the loading area, and immediately sent for delivery to
downstream customers.
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Warehousing:
Warehouse Design
Essential elements in a warehouse are:
• an arrival bay, or dock, where materials coming from suppliers
are delivered, checked and sorted;
• a storage area, where materials are kept in stock;
• a departure bay, or dock, where customers’ orders are
assembled and sent out;
• a material handling system, for moving materials around;
• an information system, which records the location of all
materials, arrivals from suppliers, departures to customers, and
other relevant information.
Warehousing:
Warehouse Design
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Warehousing:
Warehouse Design
Warehousing:
Warehouse Design
Material handling equipment
1. Manual warehouses: trolley, handtrucks, and carousels – Manual warehouses only work if the items are small and light
enough to lift, with shelves that are low enough to reach and close
together to reduce walking.
2. Mechanized warehouses: reach trucks, order-picking
machines, forklift trucks, cranes, towlines, conveyors, tractors
or trains, and carousels.
3. Automated warehouses. High storage areas, AGVs, high
speed stacker cranes, robots, and a warehouse management
system to record material locations, and control all movements.
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Warehousing:
Packaging
• Collecting together materials into these standard packages is
called unitization to form unit loads.
• Packaging serves four basic functions:– identifies the product and gives basic information;
– protects items while moved through the supply chain;
– makes handling easier;
– Assists in marketing, promoting the product, advertising and
giving information to customers.
• 2 types of packaging:– the interior, or consumer packaging, is designed for the customer and
includes the marketing and promotional materials.
– the exterior, or industrial packaging, is designed to identify the
contents, give information to organizations in the supply chain, protect
the contents, and make handling easier.