Description

This curriculum spans the design and execution of inventory control systems across procurement and supply chain functions, comparable in scope to a multi-workshop operational redesign or an internal capability program for supply chain planners in a complex, multi-site organisation.

Module 1: Strategic Inventory Classification and Categorization

Selecting between ABC, XYZ, and ABC-XYZ hybrid models based on demand variability and item criticality in multi-site operations.
Defining service level targets for each category that align with business unit requirements and financial constraints.
Implementing dynamic recategorization rules triggered by shifts in consumption patterns or supplier lead times.
Resolving conflicts between procurement’s cost-minimization goals and operations’ availability requirements during classification workshops.
Integrating risk-based scoring (e.g., supply disruption, obsolescence) into classification frameworks for high-value spares.
Configuring ERP systems to enforce category-specific procurement rules such as review frequency and approval thresholds.

Module 2: Demand Forecasting and Planning Integration

Choosing between statistical forecasting models (e.g., exponential smoothing, ARIMA) based on data history and seasonality.
Establishing cross-functional S&OP meetings to reconcile procurement forecasts with sales and production plans.
Adjusting baseline forecasts for known events such as plant shutdowns, promotions, or regulatory changes.
Managing forecast overrides with audit trails to prevent bias and maintain model integrity.
Aligning forecast granularity (SKU-location-time) with inventory control requirements and system capabilities.
Implementing safety stock formulas that incorporate forecast error and service level targets for each item-location.

Module 3: Safety Stock and Replenishment Model Design

Calculating safety stock levels using probabilistic models that account for lead time variability and demand distribution.
Selecting between min/max, reorder point (ROP), and periodic review systems based on supplier reliability and ordering costs.
Setting lead time assumptions using actual supplier performance data rather than contractual SLAs.
Adjusting safety stock for items with lumpy or intermittent demand using bootstrapping or Croston’s method.
Validating model outputs against historical stockouts and excess inventory events.
Implementing automated replenishment rules in ERP or MRP systems with exception alerts for manual review.

Module 4: Supplier Collaboration and Lead Time Management

Negotiating consignment or vendor-managed inventory (VMI) agreements for high-variability, low-visibility items.
Mapping end-to-end lead times including order processing, production, shipping, and customs clearance.
Establishing shared KPIs with suppliers such as on-time in-full (OTIF) and forecast accuracy.
Implementing buffer stock at strategic points when dual sourcing is not feasible for single-source items.
Using blanket purchase orders with scheduled call-offs to reduce lead time exposure for long-cycle items.
Conducting root cause analysis of recurring lead time deviations and triggering supplier improvement plans.

Module 5: Inventory Optimization Across Multi-Echelon Networks

Determining optimal stocking locations in a network with central warehouses, regional DCs, and plant stores.
Allocating inventory between echelons using push vs. pull strategies based on demand aggregation and transport frequency.
Modeling transshipment policies between locations to reduce emergency expediting costs.
Setting transfer lead times and costs in optimization tools to reflect actual logistics constraints.
Reconciling central procurement targets with local site service level requirements.
Updating network models after mergers, facility closures, or changes in transportation lanes.

Module 6: Obsolescence, Excess, and Lifecycle Management

Defining write-off thresholds and review cycles for slow-moving and non-moving inventory.
Integrating product lifecycle stages (introduction, maturity, phase-out) into procurement and stocking policies.
Executing last-time buy decisions with engineering and production teams before end-of-life notices.
Establishing cross-functional disposition boards to evaluate reuse, return, or disposal options for excess stock.
Tracking obsolescence risk in new product introductions by analyzing commonality with existing inventory.
Implementing system flags for items approaching expiration or shelf-life limits in regulated industries.

Module 7: Performance Measurement and Continuous Improvement

Defining and tracking inventory KPIs such as turns, days of supply, stockout frequency, and carrying cost.
Segmenting performance metrics by category, business unit, and location to identify improvement opportunities.
Conducting root cause analysis of excess inventory using Pareto analysis and process mapping.
Aligning incentive structures with inventory health rather than purchase price variance alone.
Implementing monthly inventory review meetings with procurement, finance, and operations stakeholders.
Using cycle count results to validate system accuracy and trigger process corrections in receiving or issue transactions.

Module 8: Technology Enablement and System Configuration

Selecting inventory control parameters in ERP (e.g., MRP type, lot-sizing procedure) based on item behavior.
Configuring automated reorder suggestions with manual override capabilities for strategic items.
Integrating advanced planning systems (APS) with ERP for multi-echelon optimization.
Validating master data accuracy including lead times, MOQs, and unit of measure conversions.
Implementing barcode or RFID systems to improve transaction timeliness and reduce shrinkage.
Designing role-based dashboards that display inventory status, alerts, and recommended actions for planners.