Programme overview
Technical depth: Practitioner · Practical mode: Inspection walkthrough
Introduction
Stock that cannot be found, counted or picked on time ties up cash and space while customers and internal users wait. In many organisations the physical warehouse and the inventory records drift apart, and replenishment settings are fixed once and never revisited. This course from Core Concept gives storekeepers, inventory controllers and warehouse supervisors the methods to lay out, operate and control a store to a consistent standard and to set stock levels on evidence. Participants apply each method in guided walkthroughs of warehouse processes and produce a Warehouse and Inventory Improvement Plan for their own site.
Course Objectives
- Assess warehouse layout, storage equipment and material flow against a structured walkthrough checklist
- Operate receiving, put-away, picking and dispatch to documented procedures using WMS functions and GS1 barcode data
- Classify stock with ABC-XYZ analysis and set reorder points, safety stock and order quantities for each class
- Keep inventory records accurate through cycle counting, variance investigation and FIFO or FEFO rotation
- Apply safety and housekeeping controls to racking, handling equipment and slow-moving, obsolete or damaged stock
- Produce a Warehouse and Inventory Improvement Plan with KPI targets for their own site
Target Audience
- Warehouse and store supervisors running daily receiving, storage and dispatch
- Inventory controllers and stock analysts maintaining records and replenishment settings
- Storekeepers and materials officers in maintenance, project and spare-parts stores
- Distribution centre team leaders responsible for picking accuracy and throughput
- Materials planners and buyers who set order quantities and stock levels
- Asset and finance staff responsible for stock counts and inventory valuation
Course Outline
Day 1: Warehouse and Inventory Foundations
- Warehouse Roles: Stores, Distribution Centres and Cross-Docks
- Inventory Types: Raw Materials, Work in Progress, MRO Spares and Finished Goods
- Inventory Carrying Cost Calculation
- Warehouse Layout and Flow Patterns: U-Flow and Through-Flow
- Current-State Warehouse Walkthrough Checklist
Day 2: Standards, Systems and Stock Models
- WMS Functions: Location Control, Directed Put-Away and Task Interleaving
- GS1 Identification Standards: GTIN, SSCC and the GS1 Logistic Label
- Unit Loads and Pallet Dimensions Under ISO 6780
- EOQ, Reorder Point and Safety Stock Models
- IAS 2 Inventory Valuation: FIFO and Weighted Average Cost
Day 3: Warehouse Operations and Stock Control
- Receiving and Put-Away Standard Operating Procedure
- Picking Methods: Discrete, Batch, Zone and Wave Picking
- ABC-XYZ Stock Classification and Replenishment Settings
- Cycle Counting Programme Design by ABC Class
- FIFO and FEFO Stock Rotation with 5S Housekeeping
Day 4: Accuracy, Safety and Optimisation
- Inventory Variance Investigation with the 5 Whys
- Slotting Optimisation by Pick Velocity and Cube
- Slow-Moving and Obsolete Stock Review and Disposal Procedure
- Racking Inspection Under EN 15635 and Load Notice Checks
- Warehouse Safety Risk Assessment Aligned to ISO 45001
Day 5: Walkthrough Practice and the Improvement Plan
- Spare-Parts Store Walkthrough: Record Accuracy and Location Control
- E-Commerce Fulfilment Centre Walkthrough: Picking Accuracy and Throughput
- Warehouse KPI Scorecard: Dock-to-Stock Time, Order Picking Accuracy and Inventory Turnover
- Warehouse and Inventory Improvement Plan Drafting
- Supervisor Review Panel and Action Priorities
Skills You Will Gain
- Warehouse Process Control
- Stock Classification
- Replenishment Planning
- Cycle Count Management
- Storage Space Utilisation
- Warehouse Safety Inspection
- Warehouse KPI Reporting
Why Attend This Course
- Return to work with a Warehouse and Inventory Improvement Plan built from a structured walkthrough of your own site
- Free up space and working capital by setting stock levels on data rather than habit
- Spot the unsafe racking, damaged stock and record errors that routine rounds miss
- Exchange practical store and distribution centre methods with peers from other sectors and countries
Conclusion
A well-run warehouse holds the right stock in the right place, with records that can be trusted. This course moves from the purpose and cost of inventory, through WMS, GS1 identification and the core stock models, to daily receiving, picking, counting and rotation, and then to the variances, obsolete stock and racking risks that erode performance. The final day applies structured walkthroughs to realistic stores and produces a Warehouse and Inventory Improvement Plan that each participant can put in front of their manager.