Duration 3 days – 21 hrs
Overview
This intermediate-to-advanced Warehouse Management Training Course is designed to enhance participants’ skills in strategic inventory control, warehouse operations management, materials planning, and performance optimization.
The course goes beyond basic warehouse tasks and dives deep into inventory KPIs, demand forecasting, stock replenishment, storage optimization, cycle counting, DIO & MOS optimization, and data-driven decision making.
Participants will learn how to apply tools, analytics, and industry best practices to improve warehouse efficiency, reduce carrying costs, and support organizational supply chain goals.
Objectives
- Understand and calculate key warehouse & inventory KPIs (MOS, DIO, DOH, Inventory Turns)
- Apply strategies to maintain optimal stock levels while reducing excess & slow-moving items
- Analyze inventory trends for forecasting and replenishment planning
- Improve warehouse layout, material flow, and storage optimization
- Apply best practices for receiving, put-away, picking, packing, and dispatch
- Implement strong cycle counting and audit systems to improve accuracy
- Understand demand forecasting and safety stock methodologies
- Use data-driven planning to minimize shortages and stockouts
- Strengthen coordination between warehouse, production, procurement, and logistics
- Identify warehouse inefficiencies and propose improvements
- Use lean, 5S, and root-cause analysis to enhance operational excellence
Audience
- Material Planners / Production Planners
- Warehouse Supervisors & Managers
- Inventory Controllers / Analysts
- Supply Chain Coordinators
- Procurement & Operations Personnel
- Logistics Professionals
- Anyone responsible for managing inventory accuracy and warehouse operations
Pre- requisites
- Basic understanding of warehouse operations
- Familiarity with inventory terminology (SKU, UOM, FIFO/LIFO, safety stock, etc.)
- Experience in warehouse, supply chain, or materials planning (recommended)
Course Content
DAY 1 – Inventory Management Essentials & KPI Mastery
Module 1: Foundations of Modern Inventory Management
- Inventory roles & functions
- Inventory classifications (raw materials, WIP, finished goods, MRO)
- ABC & XYZ analysis for prioritization
Module 2: Key Performance Indicators (KPIs)
- MOS (Months of Supply) – calculation, interpretation, optimization
- DIO (Days Inventory Outstanding) & DOH (Days on Hand)
- Inventory turnover ratio
- Service level, fill rate, order accuracy
Module 3: Inventory Control Techniques
- Safety stock & reorder point formulas
- EOQ, MOQ, ROP concepts
- Managing slow-moving & obsolete inventory
- Forecasting and demand planning basics
DAY 2 – Warehouse Operations Excellence
Module 4: Warehouse Layout & Storage Optimization
- Designing effective warehouse layouts
- Space utilization planning
- Material flow optimization
- Racking, shelving, pallet systems
Module 5: Warehouse Operations & Best Practices
- Receiving procedures & quality checks
- Put-away strategies
- Picking strategies (batch, wave, zone, FIFO/LIFO)
- Packing & dispatch best practices
- Preventing discrepancies and losses
Module 6: Accuracy, Audits, and Cycle Counting
- Cycle counting methods (ABC, opportunity counting)
- Root cause analysis for variances
- Inventory reconciliation
- Barcode, RFID & digital tracking
DAY 3 – Advanced Planning, Optimization & Analytics
Module 7: Material Planning & Replenishment Mastery
- Material planning workflows
- Aligning production, warehouse, and procurement
- Demand variability and buffer strategies
- Optimizing MOS & reducing DIO using real cases
Module 8: Digital Tools & Automation
- WMS (Warehouse Management Systems) overview
- Integration with ERP & supply chain platforms
- Real-time inventory visibility
- Automation trends (scanners, IoT, RFID, robotics)
Module 9: Operational Excellence & Lean Warehouse
- 5S & Kaizen applications in warehouse
- Eliminating waste in warehouse processes
- KPI dashboards and reporting
- Continuous improvement techniques
Module 10: Case Studies, Workshops & Action Planning
- Real-world scenarios for MOS/DIO control
- Inventory analysis and decision-making exercises
- Developing a personal improvement plan
- Final Q&A and coaching session
