How To Fix Your Worst Inventory Issues | LaceUp Warehouse Management System
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- เผยแพร่เมื่อ 22 พ.ค. 2024
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Most of my distributors constantly have errors in their inventory. Their inventory is either over or short and they have no idea what is wrong nor how to fix it. Having seen many of these issues over the years, I wanted to take some time to outline what you can do to resolve your inventory issues within each warehouse process. In this video, we will outline inventory problems in the following processes:
1. Receiving inventory - This includes problems encountered when receiving purchase orders, creating item receipts, and counting product coming from your vendors
2. Checking in inventory - This includes placing product or a product pallet into its been locations
3. Picking an Order - This includes picking product in order to deliver/ship an order
4. Cycle Counts/Inventory Adjustments - This includes errors encountered while doing physical inventory counts of products
5. Transferring - Includes errors experienced when transferring between bin locations and loading product onto a truck
6. Route Returns - This includes the errors experienced when the trucks return product at the conclusion of the route back to the warehouse
If you implement these processes within your inventory, you will see an uptick in inventory accuracy, a decrease in overages/shortages, a decrease in the need for daily cycle counts, and an overall stable inventory.
Enjoy the video!
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I'm from Mexico and in my job we have all these problems, our inventory confidence is 30%. Your video is really helpful, thanks a lot.
Thank you Jesus. I appreciate it. God bless
Try assertive industries. they will get your company's inventory together and implement a inventory tracking system that comes with the services. Reach out to them. They are very professional and efficient. They also do international contracts.
Agree, I remember counting every piece that came in and another co-worker took a piece and hid it in order to get me in trouble so make sure there is cameras...to find out the truth.
I think you are doing the right thing with your content for your business as well as giving value. Thank you and best of luck :)
Thank you so much. This motivates me to keep going. Best of luck to you as well.
you really know warehouse challenges well. You have a lot of experience and hands on knowledge. Thank you
I appreciate that!
The warehouse where I’m working we have a terrible problem with the inventory and is looks like nobody cares, but at the same times they cares about it.
The main problem is because the receiving they move to the locations many time without check if everything is correct, in that process sometimes we are short of locations and the person who received and put in the locations think is very easy see a location with a single item just move to a random place and put the new items in that spot.
Later the pikers pick items wrong, they are lazy to put back in the original locations and just left everywhere near by, or if you have a pallet with 10 items and just have to pick 9, the 1 left must to put in the location, but they are lazy and just left in a different locations.
Later when we do inventory manually with a simple paper, we noticed all the items wrong locations, we make a list where they are, but the office just keep the paper and don’t make the change in the system to control the inventory.
And in the last moment when we are we the last units we go walking all the warehouse to find those last items.
This is a total mess.
Try assertive industries. they will get your company's inventory together and implement a inventory tracking system that comes with the services. Reach out to them. They are very professional and efficient.
Another great video!
Implementation of checkers helped to reduce amount of errors, but some percentage of errors still remained. So that's why, in my team, pickers take a photo of products before packing it, to track back the errors.
Nicely explained
Mickey awesome tips!
Decent sttuff, respect. Thanks bud.
Really helpful thank you!
Proper warehouse inventory should know these tips . This just the basics
Facts
From Malaysia, thanks for the input👍🏼
Great video, so true, Thank you
Agree... with your statement
Great tips, thanks for sharing
Thank you so much for your comment :)
Nice stuff.
Great content thank you
Thanks!
Thanks
Awesome bro. 👌🏾
Thanks again 👍🏻🙏🏻
Great, useful video! 🙌 You can also improve your warehouse management system by using inventory mgmt softwares!!
Hi Mikey, great video on the insight. How do you manage a SKU that changed packaging and now I have 2 different cartonization configuration in my WMS for the warehouse? can WMS handle that situation? Ex: pillow that was 1pcs/carton" now is "5 pcs/carton". My immediate worries is my receiving and picking will get confused and messed up.
His hair cut n all t-shirt r 🔥
Thanks for your supportive comment :)
awesome!!!!
Put-away or Replenishing could also have an impact of inventory discrepancies, by not paying attention when a personnel missed scanning the location, missed count.
The check out machine and warehouse barcode readers and so chose really good bar code reader that can not be hacked
Can you provide any guidance on shipping ID labels vs FNSKU labels? I've shipped several pallets for boxes sold as set and AMZ warehouses are marking receiving a lot mroe than I send, which means they are opening boxes. I don't know how to stop this. Amazon support is clueless and takes too long.
please that was a great presentation,may you please delve into Assessing stock status for me?
Thank you for the information! On hiring a checker: in the quality world, quality checks in some areas are a waste of resources. You're not getting to the root of the problem by checking orders before they go out. So how do you solve the root of the problem if it's caused by someone being inattentive? We run into this issue fairly regularly and it's not quite grounds to let a particularly employee go, but we can't move them to another area either.
Great point Rick. The issue is that the root of the problem is unsolvable. The employee could pick the wrong item, count incorrectly, misplace the item in a packing bin, ETC. There are countless errors the employee can make. Therefore, I've only seen 3 solutions.
1. If the cost of these problems is small, let them go.
2. If the cost of these problems is large, you need someone to spot check transactions. This won't catch all errors, but at least you'll know what % of accuracy you have. Having someone pay will make the picking staff pay attention.
3. Change the way you pick. Pick by batch/wave, and have someone else pack. This may make your entire fulfillment more accurate, and bakes in a check process by default.
Hope this helps. Happy to see you going through this journey!
God Bless,
Mickey
@@Laceupsolutions Can I pick your brain about one more issue related to the above comment? Our inventory system isn't currently set up for barcoded locations and product but we are looking to implement this over the next year. In the meantime, we are getting absolutely slammed with incoming product and we've found that one of our biggest time-consuming tasks is labeling pallets of product (I work in the fastener industry).
My take on this is that we shouldn't have pallet labels at all since each individual box is already labeled. The receiver has to do a product inquiry in the inventory system and copy/paste some information into an Excel sheet, then print them off. Then they're affixed to each pallet and stamped "Quality Approved" once they've been inspected. Most videos and websites I've seen only have barcoded inventory systems, but if the vendor is labeling the boxes how they're supposed to already, isn't it pointless to print off a full 8 1/2" x 11" page of redundant information in bigger text? I'm trying to present this to management to show it's unnecessary but most of our redundancies seem to come down to preventing human error...which, as I said, should be avoided 99% of the time if everyone in the chain is following procedures. Thoughts?
@@rick98765 I'm working on a project that will recognize any label on any pallet, but it is a difficult project because you have to decipher the label structures. I would say that if you could find someone that has an interface that let's you pre-program the label structures and later assign the label structure to the vendor, you would technically be able to scan anything that you receive. I'm about 6months from having this tool ready to go and will be available in our enterprise product. I would recommend for you to find a WMS that has already figured this out. If you can't we can discuss it in more detail on a phone call. If you're interested, please reach out to me at mickey@laceupsolutions.com
Nice!
Thank you so much for your support. It is appreciated.
Thank you for your comment. I appreciate your feedback.
Thank you for your advice!
I don’t understand how can you protect yourself from the back office miss typing?
The only way is through a system. Otherwise, there is no way :(
Warehouse is so freaken easy but ppl make it so much harder on themselves.... so aggravating cuz the next worker who comes along gets screwed over... aka ex: digging for the fifo lpn.
Data Cleansing and Data Capturing standards are the foundation for inventory management
Please explain your comment, thanks.
Hey, awesome video! You’ve just earned a new subscriber! Quick question for you: we are a Tyre Wholesaler and have racks full of tyres, (so they look similar).
We currently manually write a sku on each product and stick on a handwritten label.
The issue we have is, doubled sku numbers when employees go out to get new sku’s when the previous item is sold.
They basically don’t see the SKU is already there and then give a new item the same
Sku causing issues for customers getting wrong products.
How can we get around that? Thanks so much!
Incredible question.... I would label upon receipt of the Tyre, and associate to a bin location using a WMS system. When picking, the user would know that every item that is residing in the bin location is labeled, and would be forced to scan the original SKU thus eliminating your problem. Any WMS with scanning should help with this function.
Just did inventory at a major sports facility that doesn't have a WMS. Very few ID labels on the racks, racks do not have locations assigned and there are no item/SKU numbers. We have to remember where the items are and sometimes items are moved to a different location. The system is very archaic however those in charge seem comfortable with it. Am curious how accurate (or efficient) an inventory can be under these conditions? All The Best!!
It’s hard to say because I don’t know the business. My best bet is hat at most the inventory is 90% accurate at the end of each business day. With a system, the inventory is 97% accurate instantaneously.
@@Laceupsolutions Appreciate it - your videos are very informative! All the best!
Hello. I am a cycle counter for automotive. I have 500 component's that come in the door. I do cc (cycle counts) every month. I have a program that tells me which ones I do for that month. Our inventory cc is horrible. When the component's come in we receice them and put a green tag on them. The green tag has multiple pull off stickers for the operators that run that materail to scan into there computer. Now my question is how do we get the operators to scan the box they r using. What they do is just keep pulling ahead. So they grab the next green tag and scan that in. Even though they r not using that box its completely full. Any ideas would great. Thank you.
Hello, I want to ask, warehousing activities in my company are storage services, the cycle is that goods enter from a partner and are delivery order to the next partner, what if there is an input of excess goods in WMS while if it is returned the system will return the goods to the partner while the physical goods are not available. If the excess input receipt is still received from the partner, it cannot send the rest of the goods because the excess input is the reason it is posted every time I send goods to my company's warehouse. The solution is how to handle excess input receipts in the warehouse management system, thanks
bonjour jai une imprimante zebra rw 420 le capteur de barre st abimé comment faire pour la répare
Say the warehouse doesn’t deal with pallets. What advice can you give? Love the videos by the way keep it up 😍
Thank you my friend. If you don't deal with pallets, its the same concept. You receive the product, the product has a label or is labeled, and the product gets assigned to a bin location. From there it is picked.
How do you perform cycle count on a pallet that has so many cases with multiple products in each case that are already picked, packed and staged and ready for shipment however it’s end of the month, flights are delayed and shipments are still in the warehouse and you have to complete a cycle count on these already staged pallets to different destinations ?
If these pallets are staged and packed, they shouldn't be counted. Because this is not pickable inventory or overstock, the staged inventory should reside in your shipping area until shipped and the packages should not be broken.
Please advise:
I just got hired to a warehouse's parts dept. that is in complete chaos and the manager told me as much when he showed me around. But, my team lead, who got hired 3 weeks ago, is very negative about what can be done and says no to most of my ideas. Yesterday, he told me I must go through the chain of command (go through him alone). But, this man is not only negative (low moral, hopeless), but also disorganized, confused, and a bit slow.
His immediate supervisor also seems to resent quick change as it might make him look bad.
How dangerous is it for me to send an outlined plan to the man who hired me 4 or 5 days ago?
Another guy hired 2 days after me is also incredulous about many of the same easily fixed problems (50 - 100 empty boxes, 250+ big boxes with one to 5 tiny parts in them that could be put in smaller boxes to give us more room).
Fixing this section of the warehouse can be done, but my team-lead thinking it cannot will get us nowhere.
I would create the document outlining your concerns and send to the person who makes decisions. As a business owner, I would appreciate it this if one of my employees took the initiative to lay out the issues of my business. LMK how it goes my friend. Wishing you the best
The pallets being unpalletised and repalletising at receipt is possibly reducing efficiency by a large factor
The cases of wrong counts in palletisation may happen in low percentage (less than 5%). Doing this activity for 100% is like increasing inefficiency by a large percentage
Easier way could be just weighing it out and seeing the weight as expected in a belt conveyor with load cells
Overall, more automation, technology, tools and less manual will help reduce manual errors better than adding more manual process or people
Warehouse people may spend more time on analysing stock and warehouse and equipments in warehouse
My two cents
Brilliant take. Thank you for sharing.
Hi thanks for your videos
But I have question my cousin has a business which he buys from the manufacturer and do a supply to a retailers but he does it manually
So he need a solution for fix this problem
Could you please guild us this but it a small business.
Thank you
Hello my friend. I would love to chat about this. Please reach out to sales@laceupsolutions.com and I will share with you pricing and a plan to help you fix this manual process.
are you ok with weighing small items vs. counting them all?
Yes. This works well for smaller items
Hi, quick question, what would you suggest about rejected material because of defect? At my job we get in large ocean shipments with no designated QC role and product sits on shelf until needed and then defects are discovered. Super frustrating when vendors won’t help, but understandable. What suggestions or tips do you have to improve this process?
Hello. I unfortunately don't know everything about your business, but the way that my customers do it is that manufacture is that they spot check. They have an employee quality checking small/random samples of their raw materials. If you can't do this, the only alternative is that your vendors help in some way.
You need to have the QC team check randomly in receiving process, if the quality is passed, put away into the storage location, if it fail, inform your purchasing dept immediately to work with vendor for their confirmation for returning back, deduct payment or destroying at your facility. The key here is you need to check when receiving and informing to vendor immediately. It is hard for vendor to confirm and support the quality if the material already stocked for months or even years at your facility.
Talking about a checker in the video I agree. But in our case we pack everything into a gaylord close it up in the closing area then ship out. What would your solution be in this case. Product is different shapes and sizes of bent tubing.
We deal with a lot of tubing and wire and found that with these types of product the double check had to be on the cutting side. not sure if you are familiar with "cut cards" but for us we have a rack where we hang our wires. When a new reel/coil/spool is hung we put the total amount being hung on the card, if their are any measurement marks for start and end of run we mark those on the cards, and then each time we have a cut the card gets marked with that amount. What we'll do is occasionally spot check the cut card to make sure the "wire cutter" (in our situation) is both marking the cuts and that the measurement marks on the product align with the math. NOt sure if this long winded paragraph helps or not. lol but i hope it does a little.
Hey Todd, sorry about the delay here. I didn't see this message until today. If you could tell me what issue you are having, it would help me answer this question. IE
1. Then product or quantity being packed into a Gaylord is incorrect
2. The wrong Gaylord is going to the customer.
Please give me some more details and I will provide some feedback. Thank you for your comment!
I work for a Co. that is just now implementing inventory controls. Row’s, Bay areas, shelving #, inventory items #’s, inventory locations & an inventory full count. They want everything done within a two month timeframe. Please note, that I am the only individual that is assigned to this task. Should I be concerned about how fast they want this done with one person assigned to the task?
This should be doable my friend. The only caveat is getting the physical labels. Those sometimes take time to manufacture. Also, you need to make sure that your bin structure is compatible with your WMS.
Please put video for warehouse to warehouse tranfer method
OK. Will do. Warehouse to warehouse transfer method on its way!
Wow....
please presentation, I want you to delve into Assessing stock status
Just saw your message. Could you plz let me know what you mean?
👏👏🤝
Hello there! Really liked your video!
I am a warehouse manager in a e-commerce business and we sell fishing and marine products. You can imagine that we have hundreds of thousands of products and many many bits and pieces due to the nature of the business.
We are using a WMS program (Soft1) so we can have track of the inventory, sales, data etc. Besides that we are implementing all the strategies that you mentioned I have a question for you.
What is the most effective way to place an order to a supplier when you have over 20 suppliers all over Europe? Keep in mind that you must take consideration of:
a) seasonality
b)sales volume
c)availability from the suppliers
Thank you in advance for your time
Kind regards
Good morning! Thank you so much for your comment. I would say that the best way is for your WMS to use sales data/re-order points, lead times, etc to project purchase orders. More sophisticated wms have EDI compatibility that can read the inventory from vendors and send purchase orders immediately, digitally. If you could combine both of the above ideas, you would streamline your purchasing process
Would a demand supply planning software also help?
Hi! Do you have partners here in philippines?
if you have overly complicated labels, your employees will make mistakes. if you put items next to each other that are easily mixed up, your employees will make mistakes. if you think your system makes sense, it probably does but only to you, the owner. if things are not easy to see visually, your employees will make mistakes. making things easy to find is hard for lazy owners who then blame their employees.
Just saw this message. Damn... This comment is on point. This is why these implementations are so damn hard because.
There is not enough manpower to audit every single delivery. I work in a medium sized manufacturing plant with thousands of skus, this would be borderline impossible.
Great point and I agree. Spot auditing would be recommended in these cases. Moreover, most of my larger customers spot audit some items on some deliveries in order to maintain a certain level of QC.
But my checker is chatting with the picker, and both of them lose attention on the counting.🤣
HAHAHAHAAHAHAH. This is great....
A person put the barcode inside the qty one time in 2017... catastrophe.
How about
1.Place a camera at the store
2. we can built an inventory app which would ask a pic conformation of the pallet which is counted and also an input button for quantity and other staff and ask the employee who did the job to click the comform button so that he take a full responsibility on what he works and send this conformation to the second hierarchy
3. This app can send a comformation link which the reciever can communicate with the up and this receiver count the pallet and Comform it if correct and discualified it if not correct and this process is again reconfirm with higher clearance and if there is a dispute we can use a photo&video conformation..
This is one case..
By the way I got this app
Congratulations on this app. It sounds incredible!
I need u to come to my job before I quit. I have no money to give you
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