Inventory Management

by Steven Brown

What is Inventory Management

 

Managing your inventory can be a competitive weapon for your company. If you don't get inventory control right, your company could ultimately go out of business. Inventory management is that important and that's what this course is all about. Welcome to Inventory Management Foundations. I'm Steven Brown, and I've been practicing the methods and techniques of inventory management for over 30 years. In this course, you'll learn the different types and costs of inventory and how to manage them. You will understand how your company's software systems create, drive, coordinate, and define your inventory levels. And you'll learn tools and methods to help you analyze and control that inventory throughout the organization. All of this will help you to better manage your inventory, one of the most important aspects of a successful business. Interested? Then let's begin! I'm ready when you are.

Inventory management defined

 

Mildred Ritter once observed that the happiest people are the ones who have enough but not too much. You see, you might be really happy to have something, but you also have the burden of having to take care of it. Having unnecessary stuff means having unnecessary burdens which does not lead to happiness and that makes sense to me. When you apply this thought at work, you'll see that it makes sense to your company as well. For your company, stuff means inventory and the key to happiness is having enough inventory but not too much. The most common definition of inventory is any company asset that is held for future use or for a future sale. You may hold on to the finished product or just the materials, parts, and components that makeup the finished product. All of this is considered inventory and that's what inventory management is all about. Planning, coordinating, and controlling every aspect of your inventory. Buying it, moving it, storing it, and selling it no matter where in the world it is. To be a good inventory manager, you need to have strong skills in these three distinct areas. First, you must be a good planner and that job is even harder in companies that operate globally as so many companies do today. Materials, parts, and components are purchased from all around the world and the product itself is made in many different factories across the globe. Having the right inventory in the right place at the right time involves some very complex global partnerships and some very strong management skills. You really must have a good plan to make that happen. Second, you also must be a good coordinator to manage inventory effectively because everyone is involved in your inventory. The purchasing department buys everything you need. The operations people turn it into a final product and transportation services move everything to the right place in a timely manner. Materials to the factory and products to the customer. You must work directly with all these departments and people. And third, you must be a good controller. Your job is to maintain the right amount of inventory that allows you to satisfy your customer as much as possible, but also to reduce cost as much as possible. These two objectives often conflict with each other. Satisfying the customer might require you to hold on to extra inventory especially the finished product just in case you need it. You don't wanna miss a sale because you don't have the inventory available. Keeping costs down can be accomplished by reducing your inventory because inventory is an investment just like machines in a factory. You not only spent money purchasing the materials, parts, and components, you have to spend money to store and manage all that material. When managing inventory, you are faced with two basic but important decisions. First, you must decide when to make the product and along with that when to order the needed materials, parts, and components. This is where your planning and coordinating skills are essential. And second, you must also decide how much to make or order. This is where you apply your controlling skills. The key to managing inventory is finding the right balance by making these two decisions appropriately. As Mildred said, make sure you have enough but not too much. To successfully manage your inventory at any level within the company, that's where you must focus, finding the right balance.

Types of Inventories

 

In the 1980s a popular business book explained that the goal of a just in time philosophy was zero inventory. Every manager in America jumped on this idea of holding no inventory. In theory, this means only having inventory needed to meet specific customer orders. Just in time. But, in practice, those managers discovered that you do, indeed, need inventory. Zero is not the answer. The key is to manage your inventory to the lowest level possible while still meeting your customer's needs, and the first step to managing inventory is to understand the different types of inventory. Because all inventory is not the same you want to manage each type in a slightly different manner, and there are four basic types of inventory. I've included a handout that outlines each type for you to follow along. First, there's cycle inventory which is the inventory needed to meet customer demand, and there are four categories of cycle inventory each requiring a different approach to inventory control. The first category is the stuff you buy from suppliers to make your product like raw materials, components, and sub-assemblies. These items can be quite expensive so you don't want to hold excessive inventory. However, you also do not want your factory to stop production because you ran out of these resources. So it is important to find the right balance, and to constantly re-evaluate this level. Second is work in process inventory also known as WIP. WIP is the factory inventory that is in the process of being made into your final product. Products that are partially completed. You operate your factory as efficiently as possible so that WIP inventory is maintained at the lowest level possible while still delivering orders on time. The third category of cycle inventory is finished goods. This is the most expensive inventory you can hold because all of your manufacturing costs are now reflected in the value of your completed product. So inventory management at this level is especially critical. This is where forecasting demand play such a critical role. The better the plan the lower your finished good inventory. The last category is maintenance, repair, and operating supplies often referred to as MRO. For the factory this includes everything from machine oil, and wipes to repair parts for equipment. Standard office supplies are in this category also. Much of this is routine, and inexpensive so most companies do not hesitate to hold additional MRO inventory to ensure operations continue smoothly. The second type of inventory is safety stock, and it applies to each of the four categories of cycle inventories. For example you might hold additional finished goods inventory just in case demand for your product increases unexpectedly, or you might hold additional raw materials in case your primary supplier is late with delivery. Safety stock is based on your analysis of risk. The third type of inventory is in transit, or transportation inventory. This includes supplies that are coming into your company, and products that are being shipped to your customers. Sometimes it makes sense to ship this inventory slower at a lower cost, and other times fast delivery is the right approach. The last type of inventory is anticipation inventory. Coordinating with your marketing department you often will increase inventory before a big sales campaign, or perhaps you make a seasonal product like ski apparel. You make inventory in advance of the winter season in anticipation of increased sales. Timing of production cycles is very important here. One important consideration for inventory management is the location of your suppliers, and your customers. Inventory management is much more difficult when suppliers, and customers are scattered widely around the world. Coordination, and communication with your key partners is important to having the right inventory in the right place at the right time. Using your understanding of the different types of inventory you can begin to analyze how your company uses different approaches to inventory management. I recommend safety stock as a good place to start an investigation.