Material Handling and Warehouse Management

Introduction

This course is designed for people working in the fields of materials and/or operations management who need to learn the basic concepts, techniques, and terminology of warehousing and material handling activities in an organization. Techniques of material control, effective warehousing, and the use of appropriate material handling equipment are covered. Completion of this course will significantly improve the participant's knowledge of material handling and warehousing and can be used in the working environment

Objectives

The objective of this course is to impart a fundamental knowledge and understanding of warehousing and material handling.  handling activities in an organization. Techniques of material control, effective warehousing, and the use of appropriate material handling equipment are covered. Completion of this course will significantly improve the participant's knowledge of material handling and warehousing and can be used in the working environment

Training Methodology

State-of-the-art business systems analysis methods and techniques are transferred by means of short, focused presentations which are followed by experiential learning workshop sessions. In these sessions, the knowledge gained is applied to real-world examples and case studies. Rapid learning of the methods and techniques is achieved by means of group work, individual work, participant discussion, facilitator interaction and constructive feedback.

Who Should Attend?

Course Outline

Day One

Session One: Managing the Warehousing

• What is the function of warehouses in a Supply Chain?
• What are the functions of warehousing?
• How a Warehouse structure should be?
• What are Warehousing operations & activities?
• What are Warehousing alternatives?
• Purpose of an efficient Warehousing System?
• What are the factors to be considered while formulating warehouse strategy?

Session Two : Warehousing Planning

• What are the prime requirements for Planning a Warehouse?
• How do you Design a Warehouse and its Layout?
• What are the Material Handling Systems and Technology?
• What are the Storage Plan for different product categories, objectives
• How will you manage a Warehouse? 

Session Three: Case Study: Facility Location Strategy of Pilot Pen

• Storage Guidelines for the Warehouse 

Day Two

Session One : Warehouse Inventory Management

• Definition of Inventory Management
• Types, nature and objectives of Inventory Management
• Reasons for holding inventory and associated cost
• Dangers of Over/Under investment in Inventory
• Classification and explanation of different inventory types
• What are the different approaches to Inventory?
• What are EOQ Model and its various approaches?
• Who is responsible for Inventory Control?
• What are the objectives and benefits of Inventory Control?
• What are different types of inventory costs?
• Terminologies used in Inventory?
• What is ABC Analysis? Its advantages & disadvantages?
• What are the Stock Checking methods?
• Who is responsible for Stock Control?
• What are the questions to be asked before adding new items to stock? 

Session Two: Warehouse Inventory Control

• What is Inventory Control?
• What are the objectives and benefits of Inventory Control?
• What are different types of inventory costs?
• Terminologies used in Inventory?
• What is ABC Analysis? Its advantages & disadvantages?
• What are the Stock Checking methods?
• Who is responsible for Stock Control?
• What are the questions to be asked before adding new items to stock?
• How can you prevent theft from warehouse?
• How can you conduct information security?
• What are the essentials for Training Warehouse Staff?

Session Three :International Commercial Terms (INCOTERMS 2010):

• What are INCOTERMS? Purposes, Uses & Application in International Trade?
• What is the difference between INCOTERMS 2000 & 2010?
• Detailed analysis of each INCOTERMS, with reference to its application and use.

Day Three

Session One : Material Resources Planning

• What is Production Planning?
• What are Materials Resource Planning and its components?
• What is the importance of Materials Management?
• What is the significance of Just-in-Time concept?
• What is Distribution Requirements Planning?
• What is the concept of “ Perfect Order”
• What are Demand Forecasting and its significance?
• What are the Replenishment Methods?
• What are the inventory rules?
• What are the Models of Inventory Planning?
• What is the need for Warehouse Analysis? 

Session Two: How to Maximize Warehouse Space When

Expansion is not an Option?

•  When does a Warehouse run out of space?
• Too Much of the Right Product, Too Much of the Wrong Product
• Poorly Utilized Space, How do you find More Space?
• Outside or Temporary Storage, Warehouse Redesign
• What are Creative Ways to Create More Space?
• Store Obsolete Material Offsite, Eliminate Inbound Inspection
• Store in the aisles, Vertical Cube Utilization , Mezzanine
• Improved Inventory Management
• Making the Most of What You Have
• Session Three :   An Overview of Voice Picking ( Video Presentation)
• Minimize movement.
• Simple administration.
• Eliminate ineffective time.
• Lowest error rate.
• Fastest order turn round.
• The correct balance of these will provide you with an appropriate level of customer service at maximum productivity and minimal cost.

Day Four

Session One : Lean Warehouse Management

• What is the objective of Lean Management?
• What are the Challenges for Warehouse & Distribution Center Managers?
• How can you define waste?
•  What are the Lean Management Tools & Techniques ?
• How Lean Management can be used in Warehouses and Distribution Centers?
• How labor activities can be considered  as waste ?
• How can you get labor support ?
• Conclusion

Session Two: Japanese House Keeping Concept in Warehouses

• SEIRI, SEITON,  SEISO,  SEIKETSU, SHITSUKE

Session Three :  Safety in Warehouses: Session One

• Safety in Warehouses : Main Types of Hazards
• How do you Manage the Risks in the following Hazards  ?
• Vehicular Movement, Loading and Unloading
• Manual Handling, Slips, Trips and Falls, Hazardous Substances
• Noise, Fire Risks, Electricity, Cold Stores

Day Five

Session One : Warehouse Personnel Performance Review

• What is Human Resources Mantra for “Productivity through People”?
• Definition & what is Performance Management?
• What is Performance Management supposed to accomplish?
• Role of Managers in Performance Management
• Principles & Ethics in Performance Management
•  How can you set Performance Targets?

Session Two: Warehouse Key Performance Indicators

• What is Key Performance Indicator?
• What is Benchmarking
• How do we benchmark and why?
• Operating cost break-up in a typical warehouse
• How to determine KPIs?
• KPIs for Receiving, Put-away, Storage, Pick-n-pack, Shipping
•  Manual Storage Types
• Conclusion

Session Three: An Overview of  Supply Chain in relation to

•      Warehousing.