Transcript Presentation Title

Materials Management
Cycle Counting
And
Physical Inventory
David McCusker, Senior Consultant
CISTECH, Inc.
[email protected]
Materials Management
Cycle Counting & Physical Inventory
Objectives
 To incorporates the best capabilities
from IM and MPA’s Physical
Inventory/Cycle Counting, then
expand with Power Architecture
technology
 Provide inventory tag support
 Provide bar code support
 Deliver customization capabilities to
greatly enhance productivity
Inventory Count Groups
Materials Management
Cycle Counting & Physical Inventory
Report
Options
will allow user
to tailor the
reports to their
preference!
Materials Management
Cycle Counting & Physical Inventory
Ease of Entry!
User can either enter
tags sequentially by
tag number
or...
Materials Management
Cycle Counting & Physical Inventory
Random Count
Entry by Item
OR by Tag
It’s the user’s
choice!
Materials Management
Cycle Counting & Physical Inventory
Count items will list in a ‘spreadsheet’ format
Columns may be moved, items can be changed, created, located…all
from this screen.
You’ll have a ‘window’ of opportunities!
Inventory Count Groups With
Subsets
• Single Warehouse
• Cycle Count Class
• Range(s)
– item numbers
within a Warehouse
– item classes
– stock locations
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Transaction Activity
By Timed Interval
Forced Count
Negative On-Hand Balance
Include
– Line Locations for REP
– Unapproved Locations for QC
Inventory Count Groups
• Turnaround Documents
– Both “Count Entry List” and “Inventory Tags”
– Bar Coding is available without PM&C being installed
• Two Inventory Lockdowns
– Entry On-Hand Quantity
• Captured at the time the actual count was entered
– Cutoff On-Hand Quantity
• Captured at the time the count was activated
Inventory Count Groups
• Speed Data Entry
– Random Entry
• By Item
• By Tag
• By Barcode
– Sequential Entry
• Warehouse/Location/Item
• Warehouse/Item/Location
• Tag Number
Inventory Count Groups
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Warehouse
Highlight Warehouse
File
Host Jobs
Physical Inventory
Inventory Count Groups
• Inventory
Count Entry
List
Inventory Count Groups
• Inventory Tags
Inventory Count Groups
Counting can
be entered
either by
Random or
Sequential
Entry
Inventory Count Groups
• Random count entry by
tag
• Random count entry by
bar-code
• Random count entry by
item
Inventory Count Groups
Sequential Entry is
the fastest format
but requires the
items being entered
to be in order.
Notice the Bypass Key.
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Cycle Count Walk Thru
Physical Inventory Walk Thru
Physical Inventory Walk Thru
Physical Inventory Walk Thru
Physical Inventory Walk Thru
Physical Inventory Walk Thru
Physical Inventory Walk Thru
Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
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COUNT GROUP- 39
INVENTORY COUNT COUNTED/UNCOUNTED REPORT
DATE 9/11/06 TIME 20.02.44 PAGE 1 AXTG660
PHYSICAL INVENTORY WALK THRU
** BOTH COUNTED AND UNCOUNTED ITEMS **
OPER MCCUSKERD
Physical Inventory Walk Thru
** COUNT 1 **
BATCH/
-----------------COUNTED--------------WHSE ITEM NUMBER DESCRIPTION
LOCATION LOT FIFO DATE TAG #
BY
DATE
QUANTITY U/M
XWH XO6000101
COLORANT - NAVY BLUE
6001
DMM
9/11/06 2000.000 KG
XWH XO6000102
COLORANT - HUNTER GREEN
6002
DMM
9/11/06 3000.000 KG
XWH XO6000103
COLORANT - SILVER SPARKLE
6003
DMM
9/11/06 40000.000 KG
XWH XO6000104
COLORANT - DEEP PURPLE
6004 DMM
9/11/06
100.000 KG
XWH XO6000105
COLORANT - BRIGHT WHITE
6005 DMM
9/11/06
200.000 KG
XWH X613
CHROME PLATED TAP PLATE
6012 DMM
9/11/06
400.000 EA
XWH X614
1/4" SCREW
6013 DMM
9/11/06
500.000 EA
XWH X615
1/2" SERRATED WASHER
6014 DMM
9/11/06
600.000 EA
XWH X616
RUBBER BASE PAD
6015 DMM
9/11/06
700.000 EA
XWH X620
BASE SUBASSEMBLY
6016 DMM
9/11/06
800.000 EA
XWH X621
CHROME PLATED CARBON
6017 DMM
9/11/06
800.000 EA
XWH X622
CHROME PLATED CARBON
6018 DMM
9/11/06
900.000 EA
XWH X623
CHROME PLATED FASTNER PIN
6019 DMM
9/11/06
10.000 EA
XWH X624
#7 SPRING
6020 DMM
9/11/06
20.000 EA
XWH X625
CHROME PLATED FOLLOWER
6021 DMM
9/11/06
30.000 EA
XWH X630
MECHANICAL INSERT ASSEMBLY
6022 DMM
9/11/06 *** VOID *** EA
XWH X632
POLYETHYLENE DRY COMPOUND
6023 DMM
9/11/06
60.000 GM
XWH X633
DISTILLED WATER
6024 DMM
9/11/06
70.000 ML
XWH X634
COLORANT BASE SOLUTION
6 025 DMM
9/11/06
80.000 ML
XWH X635
RUBBER COMPOUND
6026 DMM
9/11/06
90.000 KG
XWH X650
SIZE 6 SCREENPRINTED BOX
6027 DMM
9/11/06
100.000 EA
XWH 1600
STAPLER, MODEL 600
6028 DMM
9/11/06
200.000 EA
XWH X610
MOLDED PLASTIC TOP
RA01
3/10/06
6009 DMM
9/11/06
110.000 EA
XWH X610
MOLDED PLASTIC TOP
RA01
8/15/06
6010 DMM
9/11/06
120.000 EA
XWH X600
MODEL DESK STAPLER (FG) RA01A1 1234567890 1/06/06 6006 DMM
9/11/06
140.000 EA
XWH X600
MODEL DESK STAPLER (FG) RA01A1 1234567890 3/13/06 6007 DMM
9/11/06
150.000 EA
XWH X600
MODEL DESK STAPLER (FG) RA01A1 1234567890 3/16/06 6008 DMM
9/11/06
160.000 EA
XWH X611
MOLDED PLASTIC BASE
RA01A1
1/06/06 6011 DMM
9/11/06
180.000 EA
REPORT TOTALS:
COUNTED ITEMS:
27
UNCOUNTED ITEMS:
0
VOIDED ITEMS:
1
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COUNT GROUP- 39
INVENTORY COUNT VARIANCE REPORT
DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670
PHYSICAL INVENTORY WALK THRU
COMPARE QUANTITY - CUTOFF
OPER MCCUSKERD
Physical Inventory Walk Thru
-------- VARIANCE -------WHSE ITEM NUMBER DESCRIPTION
U/M
COUNT
COUNTED QTY COMPARE QTY QUANTITY
LOCATION BATCH/LOT FIFO DATE TOLERANCE UNIT COST
XWH XO6000101
COLORANT - NAVY BLUE
KG
1*
2000.000
2000.000
10.5000
(W) Item exists in another count group.
XWH XO6000102
COLORANT - HUNTER GREEN
KG
1*
3000.000
3000.000
10.5000
(W) Item exists in another count group.
XWH XO6000103
COLORANT - SILVER SPARKLE
KG
1* 40000.000
40000.000
420000.0000 Y
10.5000
(W) Item exists in another count group.
XWH XO6000104
COLORANT - DEEP PURPLE
KG
1* 100.000
100.000
1050.0000 Y
10.5000
(W) Item exists in another count group.
XWH XO6000105
COLORANT - BRIGHT WHITE
KG
1* 200.000
200.000
2100.0000 Y
10.5000
(W) Item exists in another count group.
XWH X613
CHROME PLATED TAP PLATE
EA
1* 400.000
400.000
28.0000 Y
.0700
(W) Item exists in another count group.
XWH X614
1/4" SCREW
EA
1* 500.000
500.000
1.7500 Y
.0035
(W) Item exists in another count group.
XWH X615
1/2" SERRATED WASHER
EA
1* 600.000
600.000
2.3400 Y
.0039
(W) Item exists in another count group.
XWH X616
RUBBER BASE PAD
EA
1* 700.000
700.000
Y
(W) Item exists in another count group.
XWH X620
BASE SUBASSEMBLY
EA
1* 800.000
800.000
56000.0000 Y
70.0000
(W) Item exists in another count group.
XWH X621
CHROME PLATED CARBON
EA
1* 800.000
800.000
24.8000 Y
.0310
(W) Item exists in another count group.
XWH X622
CHROME PLATED CARBON
EA
1* 900.000
900.000
27.0000 Y
.0300
(W) Item exists in another count group.
XWH X623
CHROME PLATED FASTNER PIN
EA
1*
10.000
10.000
.0550 Y
.0055
(W) Item exists in another count group.
AMOUNT
OU
21000.0000 Y
31500.0000 Y
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count/Physical Inventory Walk Thru
Cycle Count Steps
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Select Items for Cycle Count
Add/Delete Items To/from the Audit Control Group
Create Cycle Count Inventory Count Group
Generate and Print Inventory Tags
Generate and Print Inventory Count Entry List
Activate the Next Count Group
Work with Inventory Count Groups
Work with Inventory Count Items
Random Count Entry
Sequential Count Entry
Generate and Print the Counted/Uncounted Items Report
Generate and Print the Variance Report
Post Count Adjustment
Physical Inventory Steps
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Create Physical Inventory Count Group
Generate and Print Inventory Tags
Generate and Print Inventory Count Entry List
Activate the Next Count Group – Required
Work with Inventory Count Groups
Work with Inventory Count Items
Random Count Entry
Sequential Count Entry
Generate and Print the Counted/Uncounted Items Report
Generate and Print the Variance Report
Post Count Adjustment
Requirements for maintaining
accurate records
• A good and well documented process for recording
all receipts, issues, and dispositions that affect
inventory unit balances
• A well thought out system of inventory locations
• Record activities which match physical activities
• Well defined responsibilities and accountabilities for
accurate records
Requirements for maintaining
accurate records
• An effective system for maintaining high
levels of training and understanding among all
employees
• An effective audit program
Cycle Counting involves:
• Counting selected items frequently and testing
their record accuracy
• Identifying causes of errors in the records
• Showing change in the quality of records as
time goes on
A Short Way to Get Started
• Get your team together and read the procedure
• Make whatever few changes to terminology that are absolutely
necessary
• Select a group of 25 items
• Make assignments including counters, warehouse supervisor,
inventory analyst, etc.
• Let management know what you are doing
• Schedule a count tomorrow
• Learn by doing
• Post the results!
Physical Inventory
Day 1
• Identify Count Personal (Counters/Checkers/Entry etc.)
• Create Physical Inventory Count Group
• Generate and Print Inventory Count Entry Lists /or Tags
• Training
Day 2
• Activate Next Count
• Count Items (Random/Sequential Count Entry)
• Generate and Print Inventory Count Reports
• Post Count Adjustments
Cycle Count Inventory
Day 3
• Identify Count Personal (Counters/Checkers/Entry etc.)
• Select and Code Items for Cycle Counting
• Create Cycle Count Inventory Count Group
• Generate and Print Inventory Count Entry Lists /or Tags
• Training
Day 4
Activate Next Count
• Count Items
• Enter Counts (Random/Sequential Count Entry)
• Generate and Print Inventory Count Reports
• Post Count Adjustments
THANK YOU