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Materials Management. Cycle Counting And Physical Inventory David McCusker, Senior Consultant CISTECH, Inc. [email protected] Materials Management Cycle Counting & Physical Inventory. Objectives

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Materials management l.jpg

Materials Management

Cycle Counting

And

Physical Inventory

David McCusker, Senior Consultant

CISTECH, Inc.

[email protected]


Materials management cycle counting physical inventory l.jpg
Materials ManagementCycle 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



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Materials ManagementCycle Counting & Physical Inventory

Report Options

will allow user to tailor the reports to their preference!


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Materials ManagementCycle Counting & Physical Inventory

Ease of Entry!

User can either enter tags sequentially by tag number

or...


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Materials ManagementCycle Counting & Physical Inventory

Random Count Entry by Item OR by Tag

It’s the user’s choice!


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Materials ManagementCycle 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!


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Inventory Count Groups With Subsets

  • Single Warehouse

  • Cycle Count Class

  • Range(s)

    • item numbers within a Warehouse

    • item classes

    • stock locations

  • Transaction Activity

  • By Timed Interval

  • Forced Count

  • Negative On-Hand Balance

  • Include

    • Line Locations for REP

    • Unapproved Locations for QC


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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


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Inventory Count Groups

  • Speed Data Entry

    • Random Entry

      • By Item

      • By Tag

      • By Barcode

    • Sequential Entry

      • Warehouse/Location/Item

      • Warehouse/Item/Location

      • Tag Number


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Inventory Count Groups

  • Warehouse

  • Highlight Warehouse

  • File

  • Host Jobs

  • Physical Inventory


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Inventory Count Groups

  • Inventory Count Entry List


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Inventory Count Groups

  • Inventory Tags


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Inventory Count Groups

Counting can be entered either by Random or Sequential Entry


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Inventory Count Groups

  • Random count entry by tag

  • Random count entry by bar-code

  • Random count entry by item


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Inventory Count Groups

Sequential Entry is the fastest format but requires the items being entered to be in order.

Notice the Bypass Key.






































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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 AMOUNT OU

  • LOCATION BATCH/LOT FIFO DATE TOLERANCE UNIT COST

  • XWH XO6000101 COLORANT - NAVY BLUE KG 1* 2000.000 2000.000 21000.0000 Y

  • 10.5000

  • (W) Item exists in another count group.

  • XWH XO6000102 COLORANT - HUNTER GREEN KG 1* 3000.000 3000.000 31500.0000 Y

  • 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.


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Cycle Count/Physical Inventory Walk Thru VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670


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Cycle Count/Physical Inventory Walk Thru VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670


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Cycle Count/Physical Inventory Walk Thru VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670


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Cycle Count Steps VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670

  • 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


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Physical Inventory Steps VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670

  • 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


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Requirements for maintaining VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670 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


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Requirements for maintaining VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670 accurate records

  • An effective system for maintaining high levels of training and understanding among all employees

  • An effective audit program


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Cycle Counting involves: VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670

  • 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


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A Short Way to Get Started VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670

  • 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!


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Physical Inventory VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670

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


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Cycle Count Inventory VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670

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


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THANK YOU VARIANCE REPORT DATE 9/11/06 TIME 20.02.45 PAGE 1 AXTG670


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