Cycle Counting: What It Is, Why You Should Use It, and How to Do It Right

[et_pb_section bb_built=”1″][et_pb_row][et_pb_column type=”4_4″][et_pb_text]

Following Cycle Counting Best Practices can save you tons of time in stocktaking

Following Cycle Counting Best Practices can save you tons of time in stocktaking

Knowing what inventory you have is a fundamental step toward forecasting how much inventory you’ll need.

But traditional stocktaking processes like a full physical inventory are often time-consuming, profit-shrinking, and headache-inducing.

Yet most small businesses only use a full physical inventory to take stock.

Well, you no longer have to suffer through a full physical inventory like most small businesses.

What’s the alternative to a physical inventory?

Cycle counting.

In this post, we’ll show you what cycle counting is, its benefits, and how it works. We’ll also show you some cycle counting best practices.

By the end of this post, you’ll know how to avoid the pain of a full inventory by performing a cycle count of your inventory instead.

What is Cycle Counting?

Cycle counting is an alternative stocktaking process that involves regularly counting a small portion of your inventory over time instead of counting your entire inventory in one sitting.

While most businesses have to shut down or work overtime to perform a full physical inventory, cycle counting allows businesses to update their inventory records without shutting down during business hours or working after closing time.

The cycle counting process is simple:

  • Choose when you will perform the cycle count
  • Choose which items in what order get counted
  • Choose how often you perform your cycle count
  • Start cycle counting

Benefits of Cycle Counting

While cycle counting can be difficult to implement at first, you’ll receive significant benefits after your cycle counting system is running smoothly.

Here are just a few benefits of cycle counting:

  • Less disruptive to business operations
  • Saves more money through reduced downtime and labor
  • Improves accuracy of stocktake because employees are less likely to make mistakes when counting a smaller volume of inventory
  • Gives you the ability to find and fix errors before they get out of control
  • Gives you a “real-time” sense of your inventory levels, leading to less over-ordering or under-ordering
  • Lets you spend less time counting inventory and more time growing your business

Cycle Counting Methods

Cycle counting is not a method in and of itself. It’s a process, and there are multiple methods for applying this process.

Below are 2 of the most popular ways for implementing cycle counting.

Control Group Cycle Counting

Control group cycle counting is especially helpful for businesses using cycle counting for the first time because it allows you to test the process and uncover errors in your method before implementing it across your entire inventory.

With this method, you will choose a small group of items that will be counted many times over a short period.

Once you’re able to perform the cycle count without any errors, and you feel confident in your process, you can now apply it to the rest of your inventory.

ABC Inventory Cycle Counting

ABC analysis of inventory is a method of sorting your inventory into 3 categories according to how well they sell and how much they cost to hold:

  • A-Items – Best-selling items that don’t take up all your warehouse space or cost
  • B-Items – Mid-range items that sell regularly but may cost more than A-items to hold
  • C-Items – The rest of your inventory that makes up the bulk of your inventory costs while contributing the least to your bottom line

ABC Inventory cycle counting uses the ABC categories to guide the cycle count process.

  • A-Items – Counted most frequently (multiple times throughout the year)
  • B-Items – Counted somewhat frequently (a few times throughout the year)
  • C-Items – Counted infrequently (once or twice throughout the year)

3 Cycle Counting Best Practices

Now that you know what cycle counting is and how it works, let’s go over some cycle counting best practices to make it easier to use in your business.

Develop a Plan for Routine Cycle Counting

Before jumping into a cycle counting routine, you should detail exactly what you’ll be counting, when you’ll be counting it, how you’ll record your counts, etc.

You could make cycle counting a part of your daily routine, or choose one day every week to do it. Whatever your plan is, write it down and stick to it.

Create a Cycle Counting Team

You have to be on the frontlines implementing cycle counting…but you don’t have to do the cycle counting yourself.

Instead, you should assemble a team to perform the actual counting. Your team can consist of one other person or a group of employees.

Regardless, make sure they understand their job responsibilities, the layout of your warehouse, and how to use the tools for counting your inventory.

Test Your Cycle Counting Methods Until You Find the Right One

The goal of cycle counting is to accurately assess your inventory levels without spending too much time counting.

To achieve this goal, you’ll need to experiment with which items get counted when, how often you count, etc.

Your first goal should be to count your entire inventory four times a year. After you hit that goal, you’ll know if you need to count it more or less, depending on your rate of inventory turnover.

Want to Know What’s Even Better Than Cycle Counting?

Small businesses use cycle counting because they can’t afford to shut down for an entire day.

Plus, shutting down your business just to count your stock is a massive headache.

So what if there was a way to know how much inventory you have WITHOUT performing a cycle count or shutting down for a full stocktake?

Well, there is.

It’s called DEAR Inventory. And you can find out how it works below.

DEAR Inventory Makes Cycle Counting Obsolete

Stop Manually Stocktaking for Good with DEAR Inventory

Stop Manually Stocktaking for Good with DEAR Inventory

DEAR automatically tracks your transactions across online and offline sales while tracking your purchase orders and shipments. It also tracks your inventory in real-time. Plus, by scanning a barcode with DEAR, it will tell you exactly how much you stock you have of that item. Forget the hassle of performing stocktakes manually. Get DEAR Inventory instead.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required

[/et_pb_text][/et_pb_column][/et_pb_row][/et_pb_section]

6 Warehouse Safety Tips That Protect Employees and Boost Productivity

Keep your people safe and happy with these warehouse safety tips.

Keep your people safe and happy with these warehouse safety tips.

What matters more to you in your warehouse, safety or productivity?

Hopefully both, right?

Unfortunately, many managers disregard basic warehouse safety tips in order to achieve marginal productivity gains.

Not only will this practice lead to reduced productivity as a result of increased injuries or accidents, but it’s unsustainable long-term.

If you value increased productivity, then you should equally value warehouse safety. The safer your warehouse, the easier it will be for your employees to work harder, smarter, longer, and better.

To get the boost in productivity you want without cutting corners and putting your employees (and business) at risk, check out our actionable list of warehouse safety tips below that you can use today.

6 Warehouse Safety Tips

This isn’t an exhaustive list of recommendations, but you can use it as a simple warehouse safety checklist to get started, and add additional items in the future as you see fit.

Train Your Employees on Proper Warehouse Safety Practices

Without well-trained staff, the rest of the tips on this list won’t matter. Accidents occur more often when an employee doesn’t know what they’re doing than when a sign isn’t posted in the right area.

For that reason, warehouse safety training for employees should be your top priority.

All new employees should be given extensive training the moment they’re hired. All existing employees should receive periodic training to refresh their memories and maintain a strong culture of workplace safety.

All managers and supervisors should be reevaluated on their knowledge of basic safety procedures to ensure they’re setting a good example for the rest of your workforce.

Ensure Employees Use Warehouse Safety Equipment

All employees, managers, and supervisors should wear proper protective equipment (PPE) at all times – regardless of how minimal or extensive your PPE may be.

In addition to wearing PPE, all employees should use the appropriate equipment for their particular job. Items that are too heavy should always be lifted with forklifts or hydraulic dollies, for example.

Even if your employees are well-trained, they could still severely injure themselves if they’re not wearing proper safety equipment.

Post Warehouse Safety Procedures and Emergency Procedures in Visible Areas

To eliminate any excuses for not following warehouse safety procedures or wearing PPE or operating the right equipment, you should post your safety policies and procedures in visible spots throughout your warehouse.

You might even consider posting warehouse safety tips and lists like this, as a constant reminder to your employees to practice safety above everything else.

Posters could describe proper lifting techniques, how to handle hazardous materials, how to operate specific machines, etc.

If accidents or emergencies occur, there should be clear instructions posted around the warehouse directing employees on what to do in that situation.

For example, you should hang posters that direct employees to the nearest eyewash stations, first aid kits, fire extinguishers, emergency exits, and so on.

You should never rely on your employees memories in an emergency. Instead, make sure all safety and emergency procedures are clearly visible throughout your warehouse.

Provide Essential Safety Amenities to Your Employees

These warehouse safety tips are designed to reduce the instance of an accident or emergency as much as possible.

To that end, your warehouse should be designed to be as safe as possible. Here are a few warehouse layout safety tips to keep in mind:

  • Separate forklift traffic from pedestrian traffic when possible to avoid collisions or falling loads
  • Ensure bright lights are positioned throughout your warehouse to guarantee clear vision whenever employees are working
  • Design workstations and equipment to be as ergonomic as possible to minimize lifting, turning, bending, or any other strained movements
  • Install guardrails and stair steps that grip footwear to reduce slips or falls

Conduct a Safety Audit of Your Equipment and Facility Regularly

Putting warehouse safety tips into practice is the easiest part of making your warehouse safe.

The hard part is maintaining safety procedures long-term. To do that, you have to conduct regular safety audits.

These audits should be performed on your machinery and equipment along with your employees.

Daily, weekly, and monthly safety checkups are necessary to identify potential hazards or unsafe working conditions.

Here are a few things to make sure of in your regular safety audits:

  • Stationary equipment is working properly
  • Warehouse vehicles are well-maintained and ready for use
  • Walkways are free of clutter or boxes
  • Spills and other messes are cleaned up
  • Stray cords are neatly put away
  • Cracks or pits in the flooring are filled or sealed
  • Lights are all working
  • Employees are wearing and using their PPE

Comply with Established Warehouse Safety Rules and Regulations

There are many workplace safety standards and regulatory bodies, both voluntary and mandatory, that exist to maintain the safest business practices.

Violating any of the voluntary standards could result in future accidents and lost productivity, while violating any of the mandatory standards could cost you tens of thousands of dollars in fines.

To give you an idea of the standards most businesses usually violate, here are OSHA’s top 10 most frequently cited standards:

  1. Fall protection
  2. Hazard communication standard
  3. Scaffolding
  4. Respiratory protection
  5. Control of hazardous energy (lockout/tagout)
  6. Ladders
  7. Powered industrial trucks
  8. Machinery and Machine Guarding
  9. Fall Protection
  10. Electrical

To keep your warehouse as safe as possible (and avoid unnecessary fines) then make sure your facility conforms to the latest standards according to the institutional bodies governing safety practices in your industry.

Beyond Warehouse Safety Tips

Like we mentioned before, these warehouse safety tips are designed to get you started on the path to a safer warehouse – there are many more things you can do to prevent accidents and protect your employees.

But hopefully this list does provide some good ideas for you to implement immediately as you move forward in identifying other ways to ensure proper warehouse safety.

For more tips on warehouse optimization in general, check out our articles on effective warehouse layout design and best practices when receiving inventory.

And if you’d like to better manage the most important thing in your warehouse – your inventory – then find out how DEAR Inventory can streamline your business today.

Let DEAR Inventory Optimize Your Business

From real-time inventory tracking to accurate customer demand forecasts, DEAR Inventory provides the tools you need to grow your business without worrying about day-to-day administrative tasks. If you’re ready to swap headache-causing spreadsheets for productivity-boosting software, then DEAR Inventory is right for you.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required

 

7 Warehouse Organization Tips That Will Increase Your Productivity Today

Use these warehouse organization tips to supercharge your productivity!

Use these warehouse organization tips to supercharge your productivity!

Do you want to reduce accidents, boost productivity, and streamline your business?

Well, here’s how to do it:

Organize your warehouse.

From receiving to storing to shipping, the layout and flow of your warehouse will determine in large part how well your business operates.

We’ll help you get your warehouse in order and improve the speed and efficiency of your employees with the following 7 warehouse organization tips.

7 Warehouse Organization Tips

Re-evaluate Your Warehouse Layout Design

Your Warehouse layout design is the bedrock of warehouse organization.

Without it, you won’t be able to optimize the rest of your warehouse.

Here are 3 major principles to keep in mind when planning (or updating) your warehouse layout:

  • Flow – meaning the uninterrupted movement of materials, people, and traffic within your building.
  • Accessibility – meaning every product and all products on pallets should be accessible by everyone, usually without the need to move one product to get to another.
  • Space – meaning the maximum warehouse space you can afford, taking into consideration storage, stock, offices, working areas, empty pallet storage, battery charging, etc.

Use Warehouse Racking Organization

Warehouse racking organization is a method of storing your inventory vertically instead of horizontally, such as on pallet racks.

This is a cost-effective way to maximize your warehouse space if you carry a lot of inventory or if you have a small warehouse and can’t afford to buy more space.

Vertical racks also allow you more space on the ground for forklifts and other trucks to easily maneuver around your warehouse, as well as more space for additional employee work areas and safety stock inventory.

Use ABC Analysis to Set Up Warehouse Inventory

ABC analysis of inventory is a method of sorting your inventory into 3 categories according to how well they sell and how much they cost to hold:

  • A-Items – Best-selling items that don’t take up all your warehouse space or cost
  • B-Items – Mid-range items that sell regularly but may cost more than A-items to hold
  • C-Items – The rest of your inventory that makes up the bulk of your inventory costs while contributing the least to your bottom line

ABC analysis of inventory is one way of applying Pareto’s 80/20 principle. The bulk of your profits will usually come from about 20{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of your total inventory.

After grouping your inventory into ABC categories, arrange your pick and pack area in a way that gives your employees the easiest access to A SKUs, then B SKUs, and finally C SKUs.

Keep Your Warehouse Clean

The more clutter in your warehouse the higher the likelihood of safety hazards and accidents, in addition to reduced productivity.

More than that, a disorganized and dirty warehouse could lead to obsolete inventory – raising your cost of inventory.

An orderly warehouse, on the other hand, will increase your efficiency and throughput, while potentially improving your lead times.

Label Warehouse Inventory

Your employees shouldn’t have to rely on memory when searching for items in your warehouse. Every SKU in your inventory should be clearly labeled for easy identification.

Keep your labeling consistent for every item (i.e. always label the bottom right corner of boxes) and include all the necessary information on every label, such as:

  • Product name
  • SKU
  • Color
  • Size
  • Date
  • Etc.

Also, consider using RFID barcodes for quick scanning and easy stocktaking.

Make Receiving Inventory Easy

Receiving inventory effectively is one of the key warehouse management tips because it sets the tone for the rest of your warehouse and inventory processes. If you screw it up, everything else will be screwed up with it.

Here are a few ways you can improve inventory receiving:

  • Optimize your receiving space by providing the proper tools and enough space to allow your employees to sort and store incoming inventory.
  • Keep your receiving space clean and organized by removing clutter and putting every tool away after using it.
  • Track inventory in real-time by implementing a perpetual inventory system in order to reduce miscounts, missing inventory, and incorrect shipments.
  • Monitor quality control by hiring a quality control manager to watch for mistakes, point out problematic procedures, and reduce the instances of inventory damage.
  • Unload received inventory quickly and safely by using the appropriate machines (i.e. forklifts and conveyor belts) and following clear safety procedures.
  • Avoid shipping the wrong items to your customers by verifying the goods received using metrics such as the description of goods, product code, batch tracking number, etc.

Regularly Review Your Warehouse Organization System

To continually improve your warehouse’s organization, you’ll need to continually review your warehouse operations.

From placement of equipment to flow of processes to effectiveness of policies, you should regularly verify that you’re maximizing your warehouse space and improving your employees’ productivity.

By formalizing a policy of “checking in” with your warehouse systems and organization, you’ll be able to quickly identify any problems in your processes that could harm your bottom line long-term if you don’t address them.

Bonus Warehouse Organization Tip: Use Cloud-Based Inventory Management

Cloud-based inventory management will help you keep your warehouse organized automatically.

You’ll be able to easily implement barcode technology, organize your inventory according to ABC categories or any other system, and know exactly where your items are for quick retrieval.

Plus, if you’re managing multiple warehouses and you can’t oversee all of them all the time, a cloud-based inventory management system delivers a bird’s eye view of each warehouse and its activities right to your computer, wherever you are in the world.

If you’re serious about warehouse organization, and you want to optimize its efficiency, then DEAR Inventory can help.

Warehouse Organization Simplified with DEAR Inventory

From real-time inventory tracking to accurate customer demand forecasts, DEAR Inventory provides the tools you need to grow your business while keeping it organized and efficient. It syncs with the best business apps (Xero, Shipstation, etc.) and it’s customizable to meet your needs whether you’re a wholesaler, manufacturer, or retailer. If you want Enterprise-level software at a fraction of the cost, DEAR Inventory is right for you.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required

 

3 Profit-Boosting Advantages of ABC Analysis of Inventory

ABC analysis of inventory can help you increase your profits and decrease your costs.

ABC analysis of inventory can help you increase your profits and decrease your costs.

How do you effectively manage different types of inventory for maximum profit and lowest cost?

You segment them into different categories, making it easier to track them and use your resources appropriately.

So what method can you use to sort your inventory?

The answer: an ABC analysis of inventory.

ABC analysis will help you view your inventory from the perspective of best-selling to least-selling, and lowest inventory costs to highest.

We’ll show you what an ABC analysis of inventory is, why it’s important, and what advantages your company can gain by implementing it.

What is ABC Analysis of Inventory?

ABC analysis of inventory is a method of sorting your inventory into 3 categories according to how well they sell and how much they cost to hold:

  • A-Items – Best-selling items that don’t take up all your warehouse space or cost
  • B-Items – Mid-range items that sell regularly but may cost more than A-items to hold
  • C-Items – The rest of your inventory that makes up the bulk of your inventory costs while contributing the least to your bottom line

ABC analysis of inventory is one way of applying Pareto’s 80/20 principle. The bulk of your profits come from about 20{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of your total inventory.

Now that you know what ABC analysis means, let’s see why should you bother using it.

What is the Purpose and Importance of ABC Analysis of Inventory?

ABC analysis of inventory allows you to separate your most important products from your least important ones so that you know which products deserve most of your resources and attention to help you boost your sales and net margins.

ABC analysis of inventory helps you keep working capital costs low because it identifies which items you should reorder more frequently and which items don’t need to be stocked often – reducing obsolete inventory and optimizing the rate of inventory turnover.

Now that you know why ABC analysis is beneficial to businesses, let’s see it in practice.

What is an Example of ABC Analysis of Inventory?

The basic principle behind ABC analysis of inventory is that not every product has equal value. Because of this, you need to sort your inventory according to its value. Here’s what this process looks like in practice:

Imagine you’re a medical supplier. For the sake of this example, you sell 3 products:

  • Diagnostics
  • Orthopedics
  • Wheelchairs

You decide to perform an ABC analysis on your inventory to understand what’s selling the best, the worst, and what costs the most to hold in your warehouse.

Although wheelchairs are the smallest part of your inventory, they make up the bulk of your sales, around 60{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3}. They would clearly go into your A category.

Orthopedics make up about 30{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of your sales, and even though it uses over half of your warehouse space, it would still go into category B.

Diagnostics carry the last 10{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of your sales while taking up a fair amount of warehouse space, but since they provide the lowest profit margins, they go into category C.

Now that you have an understanding of why and how ABC analysis of inventory works, let’s look at a few of its advantages to your business.

What are the Advantages of ABC Analysis in Inventory Management?

Better Forecasting

ABC analysis of inventory helps you effectively forecast demand by splitting your inventory into categories that are based on customer demand.

Smarter Negotiations with Suppliers

After analyzing your inventory and sorting it into A, B, or C categories, you’ll know which products you should focus on buying at the lowest price, and which suppliers of those products you should negotiate with to bring their prices down so you can maximize your profit margins.

Strategic Pricing

Since you know items in category A are your best-sellers, you may be able to raise the prices of those products for increased revenue.

Whereas, with products in category B or C, you know you may have to use creative sale techniques like product bundling or social media sales to move these products out of your warehouse.

What is One Tool You Should Use With an ABC Analysis of Inventory?

ABC analysis of inventory only works if you’re effectively tracking and monitoring your orders and sales.

Without clear insight into inventory KPIs and other metrics, you won’t be able to sort your inventory into ABC categories.

There is one tool, however, that will provide those data points:

Cloud-based inventory management.

And a really good cloud-based inventory management system will give you much more than just solid reports, it will allow you to batch track your inventory, streamline your stocktaking process, and help you achieve inventory management best practices.

Where will you find a good cloud-based inventory management system?

Right here at DEAR Inventory.

Let DEAR Inventory Optimize Your Business

From real-time inventory tracking to accurate customer demand forecasts, DEAR Inventory provides the tools you need to grow your business without worrying about day-to-day administrative tasks. If you’re ready to swap headache-causing spreadsheets for productivity-boosting software, then DEAR Inventory is right for you.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required

A Simple Guide to the Lean Manufacturing System

The Lean manufacturing system is an effective way to reduce waste and boost profits.

The Lean manufacturing system is an effective way to reduce waste and boost profits.

Do you want to decrease waste and increase the quality of your products?

How about decreasing your cost of inventory and increasing your profit margins?

You’d probably like to boost your productivity too, right?

These improvements are usually hard to come by in manufacturing.

But companies around the world are reaping these benefits by implementing one proven manufacturing method…

The Lean manufacturing system.

We’ll show you what this system is, the key principles behind it, the major waste reductions you can expect from it, and the essential tools you’ll need to implement it.

By the end, you’ll have a firm understanding of Lean manufacturing and how it can transform your factory into an efficient powerhouse.

What is the Lean Manufacturing System?

The Lean manufacturing system, often referred to as Lean manufacturing, Lean production, or simply “Lean” is a system for maximizing product value for the customer while minimizing waste without sacrificing productivity.

One of the first major pioneers of “Lean thinking” (although he didn’t know it) was Henry Ford who was a major sponsor and promoter of the assembly line.

But Lean manufacturing as we know it today has its roots in the Toyota Production System (TPS), which was created by Taiichi Ohno and Eiji Toyoda in Japan between 1948 and 1975.

Before it was known as TPS, they simply called it just-in-time manufacturing.

There were 3 things the Toyota Production System attempted to prevent:

1. Muda

Muda is the Japanese term for “waste.” Muda is everything in your manufacturing process that creates waste or causes constraints on creating a valuable product.

According to the Lean Enterprise Research Centre (LERC), 60{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of all activities in manufacturing production add no value at all.

According to TPS, there are 8 wastes you should work to eliminate:

  1. Defects – The mistakes that require additional time, resources, and money to fix.
  2. Overproduction – When those who receive the output aren’t ready for it or don’t need it because workers continue to produce more unnecessarily.
  3. Waiting – When work has to stop because someone is overwhelmed, something broke down, you’re waiting for approval or materials, or because you’ve run out of something.
  4. Not utilizing talent – Under-utilizing peoples’ talents, skills, and knowledge (not part of the original TPS wastes, but is increasingly sighted as a waste by current Lean manufacturers).
  5. Transportation – Too much transportation, leading to increased costs, wasted time, and the increased likelihood of product damage and deterioration.
  6. Inventory excess – When there is supply in excess of real customer demand, which masks real production.
  7. Motion waste – Any excess movement, whether by employees or machines, that doesn’t add value to the product, service or process.
  8. Excess processing – Any task that is processed more than required

These 8 wastes can be remembered using the acronym DOWNTIME.

2. Mura

Mura is the Japanese term for “unevenness in operations.” Mura is everything that creates inconsistent and inefficient work flows.

An example of Mura would be if you stocked a truck with fewer pallets than it can hold for one trip and then stocked it with more pallets than it could adequately hold for a second trip – resulting in longer lead times.

3. Muri

Muri is the Japanese term for the “overburdening of people and equipment.” Muri is all tasks or loads that put too much stress on your employees or machines.

Muri can cause employee burnout – as in the case of having too much work to do and not delegating a portion of it to someone else.

Or, Muri can cause the total breakdown of a factory machine – as in the case of running production for too long or with too many products than is allowed by the standards of that machine.

By minimizing or eliminating Muda, Mura, and Muri the proponents of TPS and the Lean manufacturing system believe you can produce the highest-quality products while increasing your revenue and productivity.

We’ll take a look at the tools that help you prevent “unevenness in your operations” and stop “overburdening your people and equipment” in a moment, but first, let’s take a look at how the philosophy of TPS gave way to the 5 cornerstone principles of Lean manufacturing.

What Are the 5 Key Lean Manufacturing Principles?

In 1996, the book Lean thinking was published, forever solidifying a whole new way of manufacturing.

The authors – James P. Womack and Daniel T. Jones – distilled the lessons they learned from observing TPS down to 5 Lean manufacturing principles.

These 5 principles are still at the core of any Lean manufacturing system.

The 5 principles are:

1. Value

The first principle of Lean manufacturing is value, which says a company should deliver the most valuable product to the customer. Value is therefore determined by the customer, not the company or its managers.

2. Value Stream

The second principle of Lean manufacturing is value stream, which says that after you’ve determined the value you’re going to provide your customers, you should map out the steps and processes required to manufacture those valuable products.

In a Lean manufacturing system, you should actually draw out every step of your process, from raw materials to finished product.

The goal is to identify every step that doesn’t create value and find ways to eliminate those steps.

3. Flow

The third principle of Lean manufacturing is flow, which says that after you’ve eliminated most or all of the waste from your system you undergo the process of ensuring all of your value-adding steps flow smoothly without interruptions, delays, or bottlenecks.

4. Pull

The fourth principle of Lean manufacturing is pull, which says that products should be built on a “just-in-time” basis so that materials aren’t stockpiled and customers receive their orders in weeks, instead of months.

5. Perfection

The fifth principle of Lean manufacturing is perfection, which says that you should make Lean thinking and process improvement a core part of your company culture.

Lean is not a static system, it doesn’t work the same for all companies, and managers aren’t the only ones who implement Lean – employees play an active role in making companies Lean, too.

To make the Lean manufacturing system more concrete and less abstract, let’s look at a few tools you’ll need to implement Lean in your business.

What Are the Most Useful and Actionable Lean Manufacturing Tools?

To get rid of Muda, Mura, and Muri there are a variety of tools you’ll need to implement and learn how to use.

Here’s a short list of some of the most important tools in the Lean manufacturing system:

The 5S System

The 5S system is a method of organizing your workplace materials for quicker access and better maintenance. This system is essential for eliminating waste that is produced by poor workstations and tools in poor condition.

The 5 S’s are:

  1. Seiri (Sort) – Remove all unnecessary items for your current production, leaving only what is necessary.
  2. Seiton (Set In Order) – Organize remaining items and label them accordingly.
  3. Seiso (Shine) – Clean and inspect your work area and everything in it every day.
  4. Seiketsu (Standardize) – Write out your standards for the Sort, Set In Order, and Shine steps above.
  5. Shitsuke (Sustain) – Apply the standards you’ve set for your company and make them habits for everyone in your organization.

Plan, Do, Check, Act (PDCA)

PDCA is a 4-step method of continual improvement in your process and products. It applies the scientific method to manufacturing so that you can iterate the best results over the life of your business.

Here is each step:

  1. Plan – Determine the goals for a process and needed changes to achieve them.
  2. Do – Implement the changes.
  3. Check – Evaluate the results in terms of performance.
  4. Act – Standardize and stabilize the change or begin the cycle again, depending on the results.

Heijunka (Production and Demand Leveling)

Heijunka (production and demand leveling) is a technique specifically designed to reduce Mura (unevenness) by producing goods in smaller batches at a constant rate.

This helps reduce lead times and reduce inventory since each product or its variant is manufactured more frequently at a predictable rate.

Kaizen (Continuous Improvement)

Kaizen is the practice of continually observing, identifying, and implementing incremental improvements in the manufacturing process.

It encourages all managers and employees to be involved in the process of manufacturing improvements.

Kaizen ensures that waste will be gradually reduced through the collective talents and knowledge of everyone in the company working together to change the smallest inefficiencies daily.

Kanban (Pull System)

The Kanban (pull system) allows employees to “pull” work into their work station when they’re ready. This prevents Muri (overburdening employees) and allows managers and employees to focus on the right tasks at the right times without wasted effort or time.

How Do You Track Inventory in a Lean Manufacturing System?

Holding inventory is typically seen as a problem in Lean manufacturing. The closer you can get your inventory to zero, the better.

But you still need a way to manage the inventory coming into your warehouse, along with your purchase orders, customer orders, etc.

Since Lean manufacturing requires you to be flexible and fast when orders come through, it’s necessary to have an inventory management system that can respond quickly and fulfill orders as fast as you need them.

You won’t get that from manual spreadsheet inventory management.

But you can get it from cloud-based inventory management.

Find out how below…

Make Lean Manufacturing Easier with DEAR Inventory

DEAR will automate purchase orders to get goods quickly when you need them, track essential KPIs for continual improvement in your processes and workflow, and give you in-depth insight into your production costs for reduced waste and increased productivity. If you’re serious about going Lean, DEAR will make the process that much smoother.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required

4 Tips on How to Effectively Plan a Warehouse Layout Design

The layout of your warehouse is the foundation of the efficiency (or lack thereof) in your operations.

From inventory management to order fulfillment, your warehouse layout design will either streamline your business processes or slow them down.

If you need help planning your warehouse layout design, we’ll show you 3 principles of an efficient warehouse layout and 4 tips for getting it done right.

By the end, you’ll have a better understanding of what you’ll need to do to design a functional and effective warehouse.

 

3 Principles of an Efficient Warehouse Layout

Before you start designing your warehouse, you should understand what you’re trying to achieve with your warehouse layout design.

Here are 3 major principles to keep in mind when planning your warehouse:

Flow

Warehouse flow can be summarized as the uninterrupted movement of materials, people, and traffic within your building.

Your first goal should be to cut down on any areas of high traffic or potential for cross-flow crashes.

So, each activity that an employee performs must be located as close as possible to the activity that precedes it and proceeds from it.

That also means materials used to perform those activities should be situated as close as possible to each workstation.

Your second goal should be to eliminate as much movement and disruption as possible.

Accessibility

Every product and all products on pallets should be accessible by everyone, usually without the need to move one product to get to another.

That means structuring your pallet racks in rows that are wide enough to accommodate pallet jacks and trucks, and stacking and stocking items strategically for minimal interference with one another.

Space

Consider how to maximize the space you can afford, taking into consideration storage, stock, offices, working areas, empty pallet storage, battery charging, etc.

With a wide variety of vertical racks and freestanding equipment, you should be able to design your warehouse in the way you need it initially, while being flexible enough to change it in the future if desired.

 

4 Tips on How to Plan a Warehouse Layout Design

Now that you know the basics of what your warehouse needs to achieve, here are a few tips on how to achieve it.

Define Your Objectives

Defining your objectives begins with the principles we outlined above and is carried forward by the specific goals your particular business needs to achieve within your specific industry.

Each business will have different objectives for their warehouse.

Some businesses want to optimize their inventory receiving, while others need more efficient pick and pack processes, and others will design their warehouses for crossdocking.

Regardless of your objectives, make sure that your warehouse design helps you achieve them.

Determine Your Warehouse Inventory Needs

After defining your objectives, you should immediately determine your inventory and storage needs. You need to plan for the amount of stock you intend to store, how big or small that stock will be, where the stock will arrive and where it will depart, etc.

What you’re storing will dictate what you need to store it. This will also inform your aisle space, pallet rack height, and other equipment you’ll need to handle your inventory.

Create an Implementation Plan

Detail all the steps required to create your warehouse layout design.

Group tasks according to projects, i.e. building pallet racks is one project, while buying pallet racking materials is one step within that project.

Allocate appropriate resources to each task and project in your plan.

After you create your plan, double-check everything, especially the time it will take to implement your plan.

Test Your Warehouse Layout Design

Right before you start installing things like pallet racks or shelves or equipment, you should walk your warehouse to make sure it’s ready for everything to be installed.

Use masking tape to outline major work areas and carry things through it, roll pallet jacks around, and get other employees to simulate work at the same time.

This will give you a visual understanding of your space and if it’s optimized or not. Any errors here will result in worse errors later.

 

What To Do After Warehouse Layout Planning

There are 2 things you should do after warehouse layout planning:

  1. Implement your plan
  2. Invest in an inventory management system

The first point is obvious.

We’ll explain the second point.

A well-designed warehouse will help you move everything efficiently.

But it won’t help you avoid stockouts or obsolete inventory.

A well-laid out warehouse may help you with lead time reduction, but it won’t help you with inventory reduction.

If you’d like to do less stocktaking and more selling, then you need a cloud-based inventory management system.

You can find one right here at DEAR Inventory.

Start your free 14-day trial today

Pros and Cons of Dropshipping: Here’s What You Need to Know

Do you want to start an ecommerce business with low overhead and no warehouse and still make a profit?

Then dropshipping is the business model you’re looking for.

But starting a dropshipping business isn’t the right choice for every entrepreneur. There are significant tradeoffs between dropshipping and traditional wholesaling.

We’ll look at the pros and cons of dropshipping and help you make the right choice for your business today.

What Is Dropshipping and How Does It Work?

Dropshipping is a business model that allows you to sell and ship products you don’t own and don’t stock.

Your suppliers – wholesalers or manufacturers – produce the goods, warehouse them, and ship them to your customers for you.

The process is simple:

– You receive an order

– You forward the order to your supplier

– Your supplier fulfills the order

While dropshipping has many benefits, it also has many drawbacks. We’ll explore both in the sections below.

What Are the Pros and Cons of Dropshipping

Many people start a dropshipping business because they think it’ll be easy to run.

“No inventory, no problem!” they say.

The truth is, it’s not “easy.” It comes with its own set of problems.

With that said, dropshipping also solves many problems for retailers and wholesalers.

Let’s take a look at the pros and cons of dropshipping to see if it will solve your business problems or if it will add to them.

Pros of Dropshipping

1. Low Startup Costs

It requires a lot of capital to stock a warehouse. You can eliminate the risk of going into debt to start your business by using dropshipping.

Instead of purchasing an extensive inventory and hoping that it sells, you can start a dropshipping business with zero inventory and immediately start making money.

2. Low Cost of inventory

The cost of inventory is one of the highest costs you’ll have if you own and warehouse stock.

You may end up with obsolete inventory – forcing you to find ways to reduce your stock – or you’ll end up with too little inventory – leading to stockouts and lost revenue.

Dropshipping allows you to avoid these issues and focus on growing your customer base and building your brand.

3. Low Order Fulfillment Costs

Order fulfillment usually requires you to warehouse, organize, track, label, pick and pack, and ship your stock.

Dropshipping lets a 3rd party take care of all of that.

Your only job in this arrangement is to make sure they get your customer orders. Everything else will be handled by them.

4. Sell and Test More Products with Less Risk

Without the constraints of a physical inventory and the costs associated with it, dropshipping allows you to update your inventory quickly, easily, and cheaply.

If you know a product is doing well for another retailer or reseller, you can immediately offer it to your customers without waiting for it to arrive in your warehouse.

Dropshipping allows you to test new items without the risk of carrying obsolete inventory. You only pay for what you sell.

Cons of Dropshipping

1. Less Control Over Order Fulfillment and Lead Times

Even though you don’t carry the cost of warehousing stock, you will pay for dissatisfied customers.

The manufacturers and wholesalers you do business with are responsible for managing and shipping your stock. If they screw up, the customer complains to you or buys from your competitor.

If you start a dropshipping business, make sure you work with high-quality partners.

2. Reliance on Other People’s Stock

Being able to offer new products immediately or stop selling slow-moving products is a major benefit of dropshipping.

The drawback to this perk is that you don’t control your supplier’s inventory. If they run out of stock, YOU run out of stock.

This will result in longer lead times and lost customers.

3. Less Profit

The hidden “cost” of dropshipping is the lack of bulk pricing.

You will likely pay more for each item you sell as compared to paying less for a large inventory of items – leading to less profit.

If you want to earn a lot of money using dropshipping, then you’ll have to sell more products than you otherwise would have if you owned and warehoused them yourself.

4. Poorer Customer Service

If your supplier delivers products late, damages them, delivers the wrong items, or otherwise screws up your customer’s order, the customer will take it out on you.

We already mentioned this problem when it comes to order fulfillment and lead times. But it extends farther than that.

You won’t be able to maintain the personal touch that retailers who manage their own inventory can provide customers. You won’t be able to quickly solve customer issues without overseeing the inventory yourself – you’ll have to deal with your suppliers to solve problems for your customers.

This “man-in-the-middle” way of helping your customers can lead to issues with your suppliers who may take a long time to do what you ask them to do, and with your customers – who will quickly get tired of waiting a long time for their problems to be solved.

Here’s What You Need to Make Dropshipping Easier

Now that you know the pros and cons of dropshipping, it’s important for you to know about a tool that you can use to make dropshipping work better for you.

We mentioned that one of the cons of dropshipping is not being in control of the inventory you’re selling – leading to potential stockouts.

But, you can use a cloud-based inventory management software that integrates with your supplier’s software so that both of you know how much inventory is in stock at any time.

This helps you as a dropshipper synchronize your marketing and sales campaigns with your supplier’s stock.

So, when any of your supplier’s customers make a sale (including you), it will update the amount of inventory in your supplier’s warehouse automatically.

If you want to minimize some of the issues with dropshipping and make it more worthwhile, then you need an inventory management system that tracks your stock levels in real-time.

Where will you find such a system?

Right here at DEAR.

Start your free 14-day trial today

Poor Inventory Management: What’s Causing It and How to Stop It

Poor inventory management can cost you time, money and your business

Poor inventory management can cost you time, money and your business

Walmart lost $3 billion in 2013 due to poor inventory management, leading to frequent stockouts.

If that’s how improper inventory management affects a mega-corporation, how do you think it would affect your business?

We don’t want to be too hyperbolic here, but poor inventory management could cost you your business.

That’s why it’s important to recognize that this kind of fundamental problem would negatively affect your bottom line and business growth long-term.

So, how do you know if you’re managing your inventory poorly?

Poor Inventory Management Symptoms

Depending on your industry, there are many signs your inventory management is bad and getting worse.

Here are the most obvious symptoms of poor inventory management:

Of course, there are usually many factors that help produce these negative symptoms, but all of them have a root connection to the way you manage your inventory.

Which leaves us with this question:

What causes poor inventory management?

Causes of Poor Inventory Management

There could be a million reasons why you’re mismanaging your inventory.

This isn’t an exhaustive list, but it does outline a few of the most probable reasons why your inventory management is suffering.

Spreadsheets

Excel inventory management is usually the first tool small-to-medium sized businesses (SMBs) use to manage their inventory.

While spreadsheets work fine in the beginning when you’re a small operation, they can quickly lead to severe issues.

In a study of errors in 25 sample spreadsheets, Stephen Powell from the Tuck Business School at Dartmouth College found that 15 workbooks contained a total of 117 errors.

While 40{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of those errors had little impact on the businesses studied, 7 errors caused massive losses of $4 million to $110 million, according to the researchers’ estimates.

Manual Inventory Tracking and Stocktaking

Along the same lines as spreadsheets, manual inventory tracking and stocktaking are suitable for small businesses but becomes time-consuming and error-prone as your company grows.

You’ll always be one-step behind your actual inventory levels, which will cause ordering issues.

If for example, your assistant manager forgets a crucial part of your stocktaking process – like updating your data – and today is when you typically make purchase orders, you may order too much and run into the problem of obsolete stock or order too little and experience stockouts.

A Large Inventory

Large volumes of inventory don’t just lead to more management headaches – they can cut into your profits as well.

Most businesses have 20-40{cb377218d5687e54e8ee9149518f87201a393a7c1db5e8076e9d750029ec0dc3} of their working capital tied up in inventory.

Inventory reduction is difficult to do, but it’s essential if you want to go from poor inventory management to great inventory management.

Inadequate Forecasting

If you don’t use or have access to accurate reports regarding sales trends, best-selling items, customer behavior, and the like – you’ll either order too much and experience the problems of a bloated inventory, or order too little and experience stockouts and lost customers.

With accurate reports, you can forecast your customers’ future behavior and order accordingly to meet customer demand without exceeding your budget.

2 Solutions to Poor Inventory Management

While we could go on with causes of poor inventory management, you probably have a good idea of why you may be in the mess you’re in – so let’s get to the solutions.

The first solution we recommend is to check out our post on inventory management best practices. It’ll walk you through 10 ways to transform the way you manage your inventory and warehouse.

The second solution is to test out our cloud-based inventory management software.

Shameless plug, we know.

But here’s why it’s a great solution to the problem of poor inventory management:

It solves most, if not all of the issues we’ve listed in this post.

  • Accurate forecasting
  • Real-time inventory tracking
  • Automated data-entry
  • Etc.

The best part is, it’s free to try for 14 days.

If you want to upgrade your inventory management, then we have the software you need to make it happen.

Turn Poor Inventory Management into Excellent Inventory Management

Our cloud-based inventory management software will help you grow your business while maintaining efficiency and accuracy in your warehouse. You’ll have in-depth insight into your customers’ buying behavior, the ability to precisely organize your inventory into categories and batches, along with streamlined integration with essential business apps for ecommerce and accounting. You’ll get all of this and more in one centralized hub that you can access from anywhere in the world.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required

Minimum Order Quantity: What It Is and How to Make It Work for You

A minimum order quantity is often seen as a necessary evil in wholesaling, retailing, and manufacturing.

Some businesses like it, some businesses hate it, and some businesses have to use it.

But what is a minimum order quantity exactly? What are its benefits for suppliers? And how do buyers effectively deal with it?

Read on to answer all of these questions and learn how suppliers can use minimum order quantities to their advantage and how buyers can make it worth their time.

What Is a Minimum Order Quantity?

A minimum order quantity (MOQ) is the lowest set amount of stock that a supplier is willing to sell. If you can’t purchase the MOQ of a specific product, then the supplier won’t sell it to you.

All MOQs vary, depending on the product.

High-ticket items that cost more to produce will usually have a lower MOQ than low-ticket items that are easy and cheap to produce.

If you’re a buyer, we’ll show you how to navigate MOQs later in this post.

If you’re a supplier, let’s look at what its benefits are to your business.

What Are the Benefits of MOQ’s for Wholesale Suppliers?

The purpose of minimum order quantities is to allow suppliers to increase their profits while getting rid of more inventory more quickly and weeding out the “bargain shoppers” simultaneously.

A minimum order quantity is set based on your total cost of inventory and any other expenses you have to pay before reaping any profit – which means MOQs help wholesalers stay profitable and maintain a healthy cash flow.

Wholesalers don’t always prefer this way of doing business, but in many cases, wholesalers are forced to sell using MOQs because they’re forced to buy a minimum of stock from the manufacturer.

Here’s an example of how to use MOQs in your business:

Let’s say you sell golf balls. For retail customers who are buying in small quantities, you sell one pack of golf balls for $10.

If you want to sell wholesale, then you should reduce your price just enough to make it a good deal for the buyer, while allowing you to make a larger profit and quickly reduce your inventory at the same time – like golf ball packs for $5 a piece with an MOQ of 100 packs.

The goal is to attract a small amount of buyers who purchase the largest amount of your stock.

How Do You Deal With MOQ’s If You’re a Buyer?

Since you know minimum order quantities are often used by wholesalers to find the best buyers and stay profitable, you can attempt to present yourself as their ideal client while negotiating lower prices or looking for the deal that is the most mutually beneficial.

Here are a few tips for dealing with MOQs and making them worthwhile:

1. Negotiate a Lower Price

If you want to make MOQs worth it, then you should start by attempting to negotiate a lower price.

The supplier may not be able to lower the price, but you’ll never know if you don’t ask.

If you develop a good relationship with a supplier, or it’s a slow time of year for them, or if they’ve overstocked their shelves, you’ll have a better chance at persuading a supplier to lower their prices.

But if the supplier is in high-demand with loyal customers, it’ll be difficult to get a deal. In that situation, if you want the product bad enough but don’t want the full minimum quantity, your best course of action would be to pay more to receive less.

2. Buy From Legitimate Wholesale Markets Online

B2B marketplaces like Alibaba or Wholesale Central help you source products from a large variety of suppliers, allowing you to easily compare prices and deals to find the one that matches your needs.

The caveat to online marketplaces is that you should still vet the suppliers you want to buy from, even if the marketplace initially vetted them.

The best part about B2B marketplaces is that you can usually find more low or non-existent MOQs online than you could otherwise.

3. Buy From a Trader

Trading companies can place one order for multiple buyers. This means you can meet the supplier’s minimum order requirement without paying full price and without taking the full inventory.

This lowers the price of the MOQ for all buyers involved and reduces the impact of holding more inventory than you need.

Beyond Minimum Order Quantities

Minimum order quantities are just one tool out of many that suppliers can use to optimize their business.

If you’re selling online wholesale, you should enforce MOQs, but you should also try reducing your shopping cart abandonment or choose the right selling environment when deciding between Amazon Seller Central vs Vendor Central.

Similarly, MOQs are just one of many hurdles that buyers have to overcome.

If you’re buying MOQs, than you should carefully consider your reorder point and rate of inventory turnover.

But If you’re a buyer or a seller, there’s one tool you both should be using:

A cloud-based inventory management system.

This will allow you to know how much you need to sell or buy in real-time, provide accurate forecasts for future demand, and enable easier stocktaking for streamlined productivity.

If you’re sick of Excel inventory management and are looking for a better option, you just found it.

Start your free 14-day trial today

How to Optimize the Pick and Pack Process with These 5 Tips

Using the proper pick and pack process methods is crucial to your company’s success.  


Using the proper pick and pack process methods is crucial to your company’s success.

You’re never done learning the basics.

And your pick and pack process is one of the most basic tasks for running a functional business.

Get it wrong, and you’ll lose money and customers.

Get it right, and you’ll streamline your order fulfillment and increase your profits.

We’ll show you the different ways you can design your pick and pack process and how to optimize it for long-term effectiveness.

But first, let’s define pick and pack.

What is a Pick and Pack Process?

Picking is the process of pulling inventory from the warehouse to be included in the customer order.

Packing is the process of gathering and packaging these items to prepare them for shipment to the customer.

The pick and pack process is a set of procedures and tools that your employees use to fulfill customer orders quickly and efficiently.

What are the Types of Pick and Pack Processes?

There are a few distinct types of pick and pack processes.

Here are 4 of them.

Discrete Order Picking

Discrete order picking is the process preferred most by small businesses.

Here’s an example of how it works:

  • You receive 2 orders
  • You pick and pack all the items for the first order
  • Then you proceed to pick and pack all the items for the second order
  • Rinse and repeat

You only ever complete the pick and pack process for one order at a time.

It’s used by small businesses very often because they usually have smaller product catalogs and order volumes and want to reduce mistakes as much as possible.

Batch Picking

Instead of fulfilling one order at a time, batch picking is a process of gathering one batch of SKUs at a time.

For example:

If you have 5 orders, and 3 of them require Widget A, while 2 of them require Widget B, you would pick all the Widget As first, then pick the Widget Bs.

This helps save time and fulfill more orders quickly – making it ideal for SMB’s with larger product and order volumes.

Wave Picking

Wave picking is a process that blends discrete and batch picking together.

Groups of similar orders are fulfilled during scheduled time frames, or waves.

The orders may have similar SKUs, similar shipping deadlines, or could simply be in close proximity to one another.

Zone Picking

Zone picking consists of different employees assigned to different zones within your warehouse and only picking items located in their specific zone.

For example:

If an order comes through that requires items from Zone A and Zone B, the picker in Zone A will gather his items and pass on the order to the picker in zone B to complete the order.

This is ideal for large businesses with a high rate of inventory turnover.

5 Tips to Optimize Your Pick and Pack Process

Regardless of the type of pick and pack process you use, there are a few fundamental basics you should follow to optimize your system.

Here are 5 of them.

Design Your Warehouse for Efficiency

Designing your warehouse for efficient picking will dramatically cut down on the time it takes to gather items for orders.

Here are some design principles to keep in mind:

  • Place top-selling items nearest the packing stations (since they’re going to be picked more often)
  • Store items that are often packed together right next to each other
  • Arrange the rest of your inventory from top-selling to least-selling

Keep Your Warehouse Well-Organized

Neatly organize every area in your warehouse to make the pick and pack process easy and fast.

Keep the floors clean and clear away any clutter to avoid accidents.

Make sure the supplies that your packers need are correctly organized around the workstation.

And ensure that when receiving inventory you put items in the same place every time for easy picking.

Program Your WMS for Easy Picking

Implement and program a warehouse management system (WMS) so that the items being picked are listed in the order the picker will find them. This is often used for discrete or wave picking processes.

Without this type of organization, pickers are forced to calculate the picking order in their heads, resulting in a lot of time wasted – a common occurrence if they’re stuck using an Excel inventory management system.

Double Check Each Order

Even with accurate software, you should have a real human double check your goods before they’re shipped.

The cost of return shipping, re-shipping the correct item, and potentially losing a customer will cost far more than spending a little extra time ensuring every item is correctly packed for every order.

Keep an Accurate Inventory Count

An optimized pick and pack process begins and ends with an accurate inventory system.

It’s hard to get an accurate inventory count using simple spreadsheets.

Instead, you should use barcodes or RFIDs on every piece of inventory and a perpetual inventory system instead of a periodic one for easy tracking and streamlined stocktaking.

Improving Your System Beyond the Pick and Pack Process

Your pick and pack process is only one essential part of running a productive warehouse.

There are many moving parts working together to keep your business operating efficiently.

The glue that holds it together is an inventory management system that tracks every item from the moment it arrives at your warehouse to the moment it’s shipped to your customer.

A powerful inventory management system will automate your ordering, integrate with your other business apps, and optimize your pick, pack, and ship process.

If that’s what you want in your business, we can help.

Optimize the Rest of Your Business Processes

With our cloud-based inventory management system, you’ll be able to track your inventory in real-time, streamline your supply chain, batch your products, and generate reports for accurate forecasting. Everything from your pick and process to your accounting systems will run smoother and more efficiently.

Start your free 14-day trial of DEAR Inventory today!

Try DEAR for Free

No Credit Card Required