Inventory best practices:
Saved in:
| Main Author: | |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Hoboken, NJ
Wiley
2011
|
| Edition: | 2. ed. |
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XVI, 336 S. graph. Darst. |
| ISBN: | 9781118000748 |
Staff View
MARC
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Record in the Search Index
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| adam_text | Titel: Inventory best practices
Autor: Bragg, Steven M.
Jahr: 2011
Contents
Preface xv
Chapter 1 Success or Failure with Best Practices 1
Types of Best Practices 1
Most Fertile Ground for Best Practices 2
Planning for Best Practices 3
Timing of Best Practices 5
Implementing Best Practices 6
How to Use Best Practices: Best Practice
Duplication 9
Why Best Practices Fail 10
Summary 14
Chapter 2 Inventory Purchasing 15
2.1 Include Suppliers in the New Product
Design Process 17
2.2 Use Supplier-Concurrent Engineering 18
2.3 Avoid Designing Risky-Procurement
Items into Products 18
2.4 Match Product and Part Life Cycles 19
2.5 Reduce Safety Stocks by Shrinking
Supplier Lead Times 20
2.6 Purchase Supplier Capacity 20
2.7 Reduce Safety Stocks by Accelerating
the Flow of Internal Information 21
2.8 Buy from Suppliers Located Close to
the Company 22
2.9 Relocate Suppliers On-Site 23
2.10 Use Local Suppliers for Rapid Replenishment 24
2.11 Consider Foreign Sourcing 24
2.12 Use Auctions for Selective Purchases 25
2.13 Compare Suppliers Based on Total
Landed Cost 26
2.14 Eliminate Approvals of Routine Purchases 27
2.15 Purchase Based on Material Requirements
Planning 27
2.16 Compare Open Purchase Orders to Current
Requirements 28
iv / Contents
2.17 Freeze the Short-Term Production Schedule 29
2.18 Share Production Plan with Suppliers 30
2.19 Obtain Direct Links into Customer
Inventory Planning Systems 30
2.20 Require Frequent Deliveries of Small
Quantities 31
2.21 Arrange for Inbound Split Deliveries 33
2.22 Arrange for Phased Deliveries 33
2.23 Adopt Rolling Schedules 34
2.24 Adopt Just-in-Time Purchasing 35
2.25 Implement Stockless Purchasing 36
2.26 Centralize Purchasing 37
2.27 Designate Major Suppliers as Lead Suppliers 37
2.28 Single-Source Products 38
2.29 Install a Supplier Rating System 40
2.30 Use Long-Term Supplier Relationships
for Strategic Purchases 41
2.31 Shift Raw Materials Ownership to Suppliers 42
2.32 Flag Changes Impacting Advance Material
Requests 44
Chapter 3 Inventory Receiving and Shipping 45
3.1 Reject Unplanned Receipts 45
3.2 Obtain Advance Shipping Notices for
Inbound Deliveries 47
3.3 Directly Enter Receipts into Computer 48
3.4 Automatically Collect Inbound and
Outbound Cube and Weight Information 49
3.5 Repackage Incoming Items into Increments
Ordered by Customers 50
3.6 Put Away Items Immediately after Receipt 51
3.7 Stage Received Goods for Zone Putaways 52
3.8 Eliminate the Receiving Function 53
3.9 Combine the Shipping and Receiving
Functions in One Area 54
3.10 Assign Docks Based on Minimum
Warehouse Travel Time 55
3.11 Require Supplier Deliveries with Open-Sided
Trucks Directly to Production 55
3.12 Ship Using Returnable Wheeled Containers 56
3.13 Use Dunnage Bags to Cushion Outbound
Shipments 57
Contents / v
3.14 Use Shippers with the Most Consistent
Delivery Performance 58
3.15 Have Delivery Person Deliver the Invoice 59
3.16 Pay Suppliers Based Only on Receiving
Approval 60
3.17 Provide Pending Shipment Information
to the Collections Staff 63
Chapter 4 Inventory Storage 65
4.1 Drop Ship Inventory 67
4.2 Cross-Dock Inventory 67
4.3 Move Inventory to Floor Stock 68
4.4 Use Temporary Storage for Peak Inventory
Requirements 70
4.5 Assign Unique Location Codes to All
Inventory Storage Locations 71
4.6 Reduce the Number of Inventory Bin
Locations Assigned to the Same Product 72
4.7 Assign Fixed Inventory Locations to
High-Volume Items 72
4.8 Segregate Customer-Owned Inventory 73
4.9 Allocate Warehouse Areas to Specific
Customers 74
4.10 Segregate Inventory by ABC Classification 75
4.11 Store High-Pick Items in Order
Fulfillment Zones 76
4.12 Adjust Case Height to Match Cubic Storage
Capabilities 76
4.13 Adj ust Case Stacking or Width to
Avoid Pallet Overhang 77
4.14 Combine Out-and-Back Inventory Moves 78
4.15 Use Different Storage Systems Based on
Cubic Transactional Volume 78
4.16 Use Modular Storage Cabinets for
Low-Storage-Volume Items 79
4.17 Use Carousels to Increase Picking Efficiency 80
4.18 Use Movable Racking Systems 81
4.19 Use Multistory Manual Picking Systems 81
4.20 Use Gravity-Flow Racking for FIFO Picking 82
4.21 Use Pallet-Flow Racks for Pallet FIFO Picking 83
4.22 Create Double-Deep Racking or Stacking
Lanes for Large SKU Pallet Volumes 83
vi / Contents
4.23 Use Push-Back Racks for Multiple
Pallet Storage 85
4.24 Eliminate Cross Bracing in Low-Weight
Storage Configurations 85
Chapter 5 Inventory Picking 87
5.1 Group Single-Line Orders and Pick in
Order by Location 88
5.2 Use Single-Order Picks for Emergency
Orders 89
5.3 For Manual Systems, Pick from the
Source Document 90
5.4 Implement Forward Picking 90
5.5 Use Wave Picking by Grouping to
Consolidate Transactions 91
5.6 Use Zone Picking to Consolidate Total
Transactions 92
5.7 Use Zone Picking with Order Forwarding 93
5.8 Use Voice Picking to Record Low-Volume
Picking Transactions 94
5.9 Use Pick-to-Light to Record High-Volume
Picking Transactions 95
5.10 Use Portable Scales to Pick Small Items 97
5.11 Pick into Multibin Carts 97
5.12 Store Kitted Inventory in an
Accumulation Bin 98
5.13 Use Standard Containers to Move, Store,
and Count Inventory 99
5.14 Issue Parts in Full-Bin Increments 100
5.15 Have Suppliers Sequence Their Parts
Deliveries 101
5.16 Avoid Restocking during a Picking Shift 101
5.17 Optimize Inventory Storage through
Periodic Location Changes 102
Chapter 6 Production Issues Impacting Inventory 103
6.1 Eliminate Incentive Pay Systems Causing
Excessive Production 105
6.2 Standardize the Number of Shifts Worked
throughout a Factory 106
6.3 Allow Production Workers to Call Suppliers
about Faulty Materials 107
Contents / vii
6.4 Invest in Smaller, Low-Capacity Machines
Rather than High-Capacity Ones 107
6.5 Purchase Machines from a Single Supplier 108
6.6 Produce the Same Parts on the Same Machine
Every Time 109
6.7 Perform Inspections at the Next Downstream
Workstation 110
6.8 Improve Periodic Equipment Maintenance 110
6.9 Shift Some Equipment Maintenance to the
Production Staff 111
6.10 Preplan Major Equipment Maintenance 112
6.11 Replace Aisles with Conveyors 113
6.12 Schedule Smaller Production Batches 114
6.13 Produce to Order Rather than to Stock 115
6.14 Reduce Container Sizes 115
6.15 Reduce Setup Times 116
6.16 Shorten Cycle Times 117
6.17 Replace Straight Assembly Lines with
Serpentine Lines 118
6.18 Reduce the Length of the Assembly Line 118
6.19 Divide the Assembly Line into Segments 119
6.20 Use Cellular Manufacturing 120
6.21 Group Machine Cells Near Common
Inventory Storage Areas 121
6.22 Position Local Cell Storage between
Workstations and Aisles 122
Chapter 7 Inventory Transactions 123
7.1 Reduce the Number of Stored Data Elements 125
7.2 Record Inventory Transactions with Barcodes 126
7.3 Record Inventory Transactions with Radio
Frequency Communications 127
7.4 Track Inventory with Radio Frequency
Identification (RFTD) 128
7.5 Eliminate All Paper from Inventory
Transactions 130
7.6 Use the Kanban System to Pull
Transactions through the Facility 131
7.7 Eliminate All Transaction Backlogs 132
7.8 Verify That Receipts Are Entered in the
Computer System at Once 133
7.9 Have Customers Order by Part Number 134
7.10 Audit All Inventory Transactions 135
viii / Contents
7.11 Compare Recorded Inventory Activity to
On-Hand Inventories 136
7.12 Immediately Review All Negative
Inventory Balances 137
7.13 Replace the Physical Count Process with
Cycle Counts 138
7.14 Use Control Groups to Locate
Transaction Errors 141
7.15 Prioritize Cycle Counts on Next-Usage Items 142
7.16 Streamline the Physical Count Process 142
7.17 Install a Warehouse Management System 145
Chapter 8 Inventory Planning and Management 147
8.1 Include Materials Managers in the New
Product Design Process 150
8.2 Reduce the Number of Product Options 151
8.3 Increase Prices for Nonstandard Options 152
8.4 Increase Prices for Small-Unit Orders 152
8.5 Convert Information Products to
Electronic Versions 153
8.6 Reduce the Number of Products 153
8.7 Reduce the Number of Customers 154
8.8 Avoid Promotions 155
8.9 Design Products with Lower Tolerances 155
8.10 Require Formal Review and Approval of
Engineering Change Orders 156
8.11 Assign Inventory Items to Classifications 157
8.12 Forecast Demand by Product Families 158
8.13 Segment Forecasted Demand into Stable
and Unstable Products 159
8.14 Centralize Responsibility for Inventory
Planning 160
8.15 Delay the Order Penetration Point as
Long as Possible 160
8.16 Use a Material Requirements Planning
System to Model Alternative Lot Sizes,
Safety Stocks, and Lead Times 161
8.17 Reduce Job Releases to Production 162
8.18 Prioritize Production Based on
Delivery Region 163
8.19 Use Variable Safety Stocks for
Fluctuating Demand 163
8.20 Convert Safety Stock to Just-in-Case Stock 164
Contents / ix
8.21 Eliminate Expediting 165
8.22 Develop a Product Substitution System 166
8.23 Question the Level of Customer
Service Provided 166
8.24 Focus Inventory Reduction Efforts on
High-Usage Items 167
8.25 Create a Visual Review System for
Noninventoried Parts 168
8.26 Eliminate Departmental Stocks 169
8.27 Install a Distribution Requirements
Planning System 170
8.28 Distribute Slow-Moving Items from
Regional Warehouses 170
8.29 Install a Hold and Flow System 171
8.30 Use Overnight Delivery from a Single
Location for Selected Items 172
8.31 Use Fair Shares Analysis to Allocate
Inventory to Warehouses 173
8.32 Periodically Rationalize the
Warehouse Network 173
8.33 Plan for Product Shutdowns 175
8.34 Create a Materials Review Board 175
8.35 Identify Obsolete Inventory via Physical
Inventory Tags 176
8.36 Plan for Service Parts Inventory Levels 177
8.37 Inspect Returned Merchandise for Usability 178
8.38 Reserve Otherwise Obsolete Inventory with
Service/Repair Designation 178
8.39 Avoid Product Obsolescence with
Shelf-Life Control 179
8.40 Create an Obsolete Inventory Budget for
Disposals 180
8.41 Batch Excess Inventory for Sale to Salvage
Contractors 181
8.42 Sell Excess Items through the Service
Department 181
8.43 Set Up a Reverse Logistics System 182
8.44 Outsource Selected Warehousing Functions 183
Chapter 9 Warehouse Layout 185
9.1 Include Other Issues than Cost in a
Warehouse Acquisition Decision 186
x / Contents
9.2 Generally Organize the Warehouse in a
U-Shaped Process Flow 187
9.3 Organize the Warehouse by Storage Zones 188
9.4 Maximize Vertical Storage Space 189
9.5 Tailor Vertical Storage Space to Manual
Picking Needs 190
9.6 Enclose Building Supports in Racks 190
9.7 Use Narrow Aisles in Manual Putaway
and Picking Zones 191
9.8 Avoid Aisles Adjacent to Outside Walls 192
9.9 Use Automated Storage and Retrieval
Systems 192
9.10 Use Automated Guided Vehicle Systems 193
9.11 Use Conveyors to Reduce Employee Travel 194
9.12 Avoid an Excessive Level of Warehouse
Automation 195
9.13 Eliminate the Quality Review Area 197
9.14 Enlarge the Receiving Area 197
9.15 Design Just-in-Time Docks for the Largest
Anticipated Trucks 198
9.16 Lock Down the Warehouse Area 199
9.17 Plan for Maximized Warehouse
Space Utilization 200
9.18 Eliminate the Warehouse 200
Chapter 10 Cost Accounting 203
10.1 Eliminate Purchase Price Variance Tracking 203
10.2 Eliminate Tracking of Work-in-Process
Inventory 205
10.3 Eliminate Scrap Reporting in the
Production Area 206
10.4 Charge the Entire Inventory to Expense 206
10.5 Use Specific Identification Costing
with RFID Tags 207
10.6 Have the Cost System Separate Value-Added
and Nonvalue-Added Activities 208
10.7 Assign Overhead Based on Square
Footage Used 209
10.8 Do Not Credit Internal Departments with
Sales When Production Is Completed 210
10.9 Report on Landed Cost Instead of
Supplier Price 211
10.10 Report on the Total Cost of Product Ownership 211
Contents / xi
10.11 Implement Activity-Based Costing 212
10.12 Assign Overhead Personnel to Specific Subplants 214
10.13 Implement Target Costing 214
10.14 Limit Access to Unit-of-Measure Changes 215
10.15 Review Cost Trends 216
10.16 Review Material Scrap Levels 218
10.17 Revise Traditional Cost Accounting Reports 220
10.18 Audit Labor Routings 222
10.19 Follow a Schedule of Inventory
Obsolescence Reviews 223
Chapter 11 Bills of Materials 227
11.1 Audit Bills of Materials 227
11.2 Conduct a Configuration Audit 229
11.3 Modify the Bills of Materials Based on
Actual Scrap Levels 230
11.4 Modify the Bills of Materials for
Temporary Substitutions 231
11.5 Eliminate Redundant Part Numbers 232
11.6 Standardize Parts 233
11.7 Review Inventory Returned to the Warehouse 234
11.8 Use Bills of Materials to Find Inventory
Made Obsolete by Product Withdrawals 235
11.9 Identify Inactive Inventory in the Product
Master File 236
Chapter 12 Impact of Constraints on Inventory 237
Overview of the Theory of Constraints 237
Overview of the Constraint Buffer 239
Alternatives to the Constraint Buffer 240
Expedite Zone 241
Buffer Manager 242
Buffer Hole 242
Buffers for Labor Operations 243
Assembly Area Buffer 243
Inventory Releases 244
Batch Sizes 244
Summary 246
Chapter 13 Inventory Policies and Procedures 247
13.1 Create a Policies and Procedures Manual 248
13.2 Train the Warehouse and Accounting
Staffs in Inventory Procedures 250
xii / Contents
13.3 Cross-Train for Mission-Critical Activities 251
13.4 Train Using Training Teams 252
Chapter 14 Inventory Measurements 271
14.1 Percentage of New Parts Used in
New Products 271
14.2 Percentage of Existing Parts Reused in
New Products 273
14.3 Raw Material Content 274
14.4 Bill of Materials Accuracy 275
14.5 Item Master File Accuracy 276
14.6 Economic Order Quantity 276
14.7 Distribution Turnover 277
14.8 On-Time Parts Delivery Percentage 278
14.9 Incoming Components Correct
Quantity Percentage 279
14.10 Purchased Component Defect Rate 280
14.11 Percentage of Receipts Authorized by
Purchase Orders 281
14.12 Percentage of Purchase Orders Released
with Full Lead Time 282
14.13 Putaway Accuracy 282
14.14 Putaway Cycle Time 283
14.15 Scrap Percentage 284
14.16 Average Picking Time 285
14.17 Picking Accuracy for Assembled Products 286
14.18 Average Picking Cost 287
14.19 Order Lines Shipped per Labor Hour 288
14.20 Shipping Accuracy 289
14.21 Percentage of Products Damaged in Transit 290
14.22 Warehouse Order Cycle Time 290
14.23 Inventory Availability 291
14.24 Delivery Promise Slippage 292
14.25 Average Back-Order Length 293
14.26 Dock Door Utilization 294
14.27 Inventory Accuracy 294
14.28 Inventory Turnover 295
14.29 Percentage of Warehouse Stock
Locations Utilized 297
14.30 Square Footage of Warehouse Storage Space 298
14.31 Storage Density Percentage 299
14.32 Inventory per Square Foot of
Storage Space 299
Contents / xiii
14.33 Storage Cost per Item 300
14.34 Average Pallet Inventory per SKU 301
14.35 Rate of Change in Inactive, Obsolete,
and Surplus Inventory 302
14.36 Obsolete Inventory Percentage 303
14.37 Percentage of Inventory X Days Old 304
14.38 Percentage of Returnable Inventory 305
Appendix Summary of Inventory Best Practices 307
Glossary 319
About the Author 331
Index 333
|
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| illustrated | Illustrated |
| indexdate | 2024-07-10T00:05:58Z |
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| isbn | 9781118000748 |
| language | English |
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| spelling | Bragg, Steven M. 1960- Verfasser (DE-588)129558990 aut Inventory best practices Steven M. Bragg 2. ed. Hoboken, NJ Wiley 2011 XVI, 336 S. graph. Darst. txt rdacontent n rdamedia nc rdacarrier Wirtschaft Inventories Inventory control BUSINESS & ECONOMICS / Accounting / Managerial bisacsh Lagerhaltung (DE-588)4034081-8 gnd rswk-swf Lagerhaltung (DE-588)4034081-8 s DE-604 HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024398443&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Bragg, Steven M. 1960- Inventory best practices Wirtschaft Inventories Inventory control BUSINESS & ECONOMICS / Accounting / Managerial bisacsh Lagerhaltung (DE-588)4034081-8 gnd |
| subject_GND | (DE-588)4034081-8 |
| title | Inventory best practices |
| title_auth | Inventory best practices |
| title_exact_search | Inventory best practices |
| title_full | Inventory best practices Steven M. Bragg |
| title_fullStr | Inventory best practices Steven M. Bragg |
| title_full_unstemmed | Inventory best practices Steven M. Bragg |
| title_short | Inventory best practices |
| title_sort | inventory best practices |
| topic | Wirtschaft Inventories Inventory control BUSINESS & ECONOMICS / Accounting / Managerial bisacsh Lagerhaltung (DE-588)4034081-8 gnd |
| topic_facet | Wirtschaft Inventories Inventory control BUSINESS & ECONOMICS / Accounting / Managerial Lagerhaltung |
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