本帖最后由 陆剑一 于 2011-10-26 16:15 编辑
Inventory Reduction How Do I Get Started? Eight Steps to Measurable Results! All of us know the importance of increasing inventory turns to decrease working capital requirements. But where do you start? Most companies have thousands or tens of thousands of part numbers in inventory. Many companies have also launched numerous initiatives that have ground to a halt and made little progress at bringing down inventory levels. Following is a no nonsense approach that will yield real results for any organization. The process is not easy and it will take some resources, but it will lead to early results. And as we all know, results build momentum . . . and yield more results! Here is how to get started. Step 1: Identify resources. Pair up a Senior Buyer, Planner and an Engineer as your basic “quick hits” team. They are going to need to devote several hours each week to this initiative. Starting with one team will be a good way to prove the concept and develop momentum. Step 2: Do a simple A-B-C analysis of your inventory spend from the past year (or other relevant period). After calculating total annualized spend by inventory line item [units consumed times cost per unit], identify the largest spend items that total 80% of your overall inventory spend. These are your “A” items. This analysis should include both purchased and manufactured items. Step 3: Compare your current on-hand inventory balances of these “A” items to an ideal inventory on-hand target. For these “A” items the ideal inventory on-hand target should be something like 3 days (of average daily usage) plus 5 days (or less) of safety stock to cover spikes in demand. Subtract the ideal units on hand from the actual units on hand and multiply by unit cost. The largest dollar differences identify the biggest potential opportunities for immediate inventory reduction. When sorted in descending order of dollar differences this list is a prioritized list for attacking the overall inventory balance. The sum of inventory dollars on-hand that is above the ideal inventory level becomes the total opportunity to pursue. You’re not likely to get the ideal inventory target in your first pass but it creates a good sense of where the biggest opportunities are hiding. Step 4: Starting with this prioritized list, select the top 20 items based on the potential opportunity to move on-hand inventory toward the ideal targets. Assign these items to your team. The team will take these 20 items and work them during the first month. Charge the team with being creative and being action oriented. Potential ways to improve the on-hand balances: Reduce the supply lead time (vendor or manufactured) so smaller and more frequent orders can be used to supply customer needs. For purchased items, consider utilizing blanket purchase orders and requiring suppliers to keep inventory on hand to fulfill your orders within a five day lead time. Reduce minimum order or run sizes. Consider alternate suppliers or distribution to shorten lead times or reduce minimum quantities. Develop a visual ordering system (e.g., Kanban), so these items are only ordered based on a visual signal. Step 5: Have a steering committee consisting of operations, materials and finance meet with the team weekly to check progress and to knock down any barriers. This weekly meeting will encourage the team to take action throughout the month rather than waiting until an end of month report out. Step 6: At the end of the month, ask the team to present their expected results to the steering committee. Actions for each item should have already been approved and taken from the weekly meetings. The team’s summary will identify three statuses for their top 20 items. Status | Meaning | Next Steps | Some Inventory Reduction Achieved | Actions in place to reduce on-hand balance | Plan and measure results weekly | Progress Made | Opportunity has been identified but more work is needed to achieve inventory reduction | Assign other resources or put on "back burner" | No progress made | No real opportunity has been identified | Skip this item and move on (for now) |
Step 7: Establish a plan to measure and report weekly progress on these items. Assign individuals from outside this team to own and report the achievement of the expected results. Results should be reviewed at the weekly steering committee meetings. Step 8: Celebrate the successes and select the next 20 items for the following month! So it’s that simple? Not really, but the trick is to find some early wins, build upon them and don’t let the team get bogged down by trying to fix everything on the first pass. Still have questions? How can working on 20 inventory items in a month really help my overall inventory position? Answer: Focusing on 20 items in a month may seem too slow, given the number of items you have in inventory, but the key is that the quick hits team is focused on items that are both high use and high inventory. As you put new actions in place, any excess inventory should burn off rapidly. More teams or more items will yield more results – just be sure to also track and countermeasure for sustainment. If we allow the quick hits team to skip the difficult items, won’t we be missing some key opportunities? Answer: A key to this process is to take a triage approach. Focus on the inventory items that can be fixed quickly, put a band-aid on some and let the really hard ones go. It is critical to find some successes and build momentum. The one-month focus will allow the team to stay fresh and see progress, without getting bogged down in year long negotiations and re-design projects. Keep a list of these projects and assign them to resources outside of the quick hits team.
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