Material Planning & Control

Material Planning & Control for Effective Inventory Management

21-22 April 2020, Doha

22-23 April 2020, Kuala Lumpur – Malaysia

26-27 April 2020, Dubai – United Arab Emirates

Material Planning & Control for Effective Inventory Management

About The Trainer:

Sekar Ponnan, is both a practitioner and an educator in the field of Logistics, Supply Chain & Procurement. He holds an MBA (General Management) from University of Hull, UK, a Bachelors Degree (Hons) in Economics from University Malaya and an Advance Diploma in Logistics Management, UK from Chartered Institution of Logistics & Transport in Malaysia. He is also a chartered member of the Chartered Institution of Logistics & Transport Malaysia.

Mr. Sekar has a solid 20 year experience in the field of Logistics, Procurement & Supply Chain gained through his work stint in big conglomerates and Multi-National Companies at various levels ranging from junior level to Executive Committee level in the areas of manufacturing, logistics service providers, implementation of supply chain management, setting up 3PL logistics management and liaison with various authorities. He has also assisted clients to improve their supply chain management and develop the integrated logistics systems, stock level reduction, improve the purchasing and inventory management performance and enhance customer service standards. In his 20 years of service at corporate world, Mr. Sekar has also covered different geographical areas from local operations to regional scope covering whole of Asia. He has wide management exposure in different areas of business; having held key management positions in Logistics Operations, Inventory Management, Procurement and Supply Chain. Mr. Sekar also serves as consultant for GLG Asia (based in Singapore), Rakan Ikhlas Sdn Bhd and Generic Business Solutions Pvt Ltd (based in Ahmedabad, India) in the field of Logistics, Supply Chain & Procurement.

Besides his work, he also actively involved himself in teaching and training. As a PSMB certified trainer, Mr. Sekar has been a corporate trainer since 2010 and he has given lectures and has conducted in-house training programmes for the companies he served and external companies that are aware of his credentials and vast practical experience ranging from negotiation skills, contract management, sourcing skills & developing savings action plans, warehouse management, Fundamentals of Procurement, Fleet Management, Supply Chain Management, Business Process Reengineering, Developing comprehensive Standard Operating Procedure for Procurement, Logistics Management, Inventory Planning & Control and Transport & Distribution. He has the unique ability to connect with people and uses humor and creative teaching techniques in his workshop sessions. He adopts a practical approach and provides relevant applications in his session. He is also able to simplify the theories and relate them to real life examples to enhance the learning process.

Who Should Attend?

  • Purchasing Executives,
  • Materials Planners, Purchasers,
  • Logistics Managers, Inventory Controllers and all those whose jobs require them to plan and organize materials to meet their organizations’ objectives.

Methodology:

  • Lectures,
  • Case studies,
  • Role-plays,
  • Group presentations,
  • Group discussions,
  • Management games.

Material Planning & Control for Effective Inventory Management:

With the knowledge and skills acquired at the end of the training programme, the trainees will be able to understand the importance of material planning and control, examine various aspects of managing materials requirements, design a systematic approach in order to prevent down times caused by materials shortages and other delays factors and plan and forecast materials in terms of economics and operational efficiency

Course Modules:

Module 1 – INVENTORY & MATERIAL MANAGEMENT

  • Inventory Management Simplified & Definition
  • Functions & Purpose of Inventory
  • The Scope of Inventory Management
  • 6 Rights of Material Management
  • Key Objectives of Material Management
  • Indicators of Material Management
  • Activity :
  • Factors to consider in Inventory control
  • Difficulties in MM & its impact

Module 2 – BASICS OF PLANNING

  • Types of Stock Holding / Inventory
  • Inventory Cost Structure
  • Cost & Benefits of Holding Stocks
  • Issues with traditional inventory planningAnalyzing Time & Inventory
    Inventory Planning for Manufacturing
  • Activity :
  • Inventory Holding Costs
  • Video – Inventory Holding Costs
  • Improvement to difficulties in MM

Module 3 – SUPPLY PLANNING

  • Production Planning
  • Master Production Schedule
  • BOM
  • Aggregate Planning
  • Logistics Capacity Planning
  • Bullwhip Effect
  • Bottlenecks
  • Capacity Planning
  • Forecasting
  • Activity :
  • Video Presentation – Bullwhip Effect
  • Minimizing Bullwhip effect
  • Identify Bottlenecks in Organization & Propose Action Plans

Module 4 – MATERIAL PLANNING & MANAGEMENT

  • Inventory Replenish Systems
  • Economic Order Quantity
  • Continuous Review System
  • Periodic Review System
  • Stock Turnover Calculation
  • ABC Analysis
  • The Min / Max – based on days coverage forward or Lead Time
  • Benchmarking Your Business
  • Daily Tracking of Book vs Physical Stocks
  • S&OP
  • Strategic Materials
  • Activity – Identify Strategic Materials & action plans

Module 5 – INVENTORY MANAGEMENT TECHNIQUES

  • Just In Time
  • Vendor Managed Inventory
  • Consignment Stock
  • First-In First-Out (Fifo)
  • Lead Time Reduction
  • Drop-Shipping
  • Cross-Docking
  • Payment Terms
  • Activity
  • Risk factors of JIT
  • Benefit of Consignment Stock

Module 6 – TOOLS FOR MATERIAL PLANNING

  • Manual Planning
  • Computer Based Planning – MRP
  • Basic Components
  • Objectives
  • Advantages & Disadvantages
  • Key Success Factors
  • Distribution Requirement Planning
  • Elements
  • Pull vs Push Systems
  • Warehouse Management System
  • Features of WMS
  • MRP Improvement Tactics

Module 7 – INVENTORY MANAGEMENT CHALLENGES

  • Integrating demand & inventory planning
  • Training Users of material management software
  • Change Management
  • Standardizing Data
  • Choosing the suitable module
  • Inaccurate Forecasting
  • Poor Communication
  • Regulatory Compliances
  • Inconsistent Sales
  • Components of Material Management Competencies
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