Course Overview
This intensive 5-day course provides comprehensive training on efficient material handling systems, inventory control techniques, and optimized spare parts management. Participants will learn best practices for warehouse operations, stock movement, and logistics management to minimize costs while maximizing productivity. The program combines theoretical knowledge with practical applications using real-world case studies and hands-on exercises.
Course Objectives
By completing this course, participants will be able to:
- Design and implement efficient material handling systems
- Apply modern inventory control techniques
- Optimize spare parts management and movement
- Utilize warehouse management systems (WMS) effectively
- Improve safety in material handling operations
- Reduce operational costs through lean principles
- Implement performance measurement systems
Who Should Attend?
This course is ideal for:
- Warehouse and logistics managers
- Inventory control specialists
- Supply chain professionals
- Maintenance managers and planners
- Operations supervisors
- Procurement officers
- Industrial engineers
- Plant managers
Detailed Course Outline
Day 1: Fundamentals of Material Handling
Module 1: Introduction to Material Handling Systems
- Principles of material handling
- Types of handling equipment (conveyors, AGVs, cranes)
- Equipment selection criteria
- Safety considerations and regulations
Module 2: Warehouse Layout and Design
- Storage systems and configurations
- Space utilization techniques
- Workstation design principles
- Case study: Optimizing warehouse layout
Day 2: Inventory Control Techniques
Module 3: Inventory Management Fundamentals
- Types of inventory (raw materials, WIP, finished goods)
- ABC analysis and classification
- Inventory accuracy methods
- Cycle counting procedures
Module 4: Modern Inventory Control Systems
- JIT and lean inventory approaches
- Kanban systems implementation
- Vendor-managed inventory (VMI)
- Hands-on exercise: Inventory simulation
Day 3: Spare Parts Management
Module 5: Spare Parts Strategy Development
- Criticality analysis for spare parts
- Stocking level determination
- Codification systems
- KPI development for spare parts
Module 6: Maintenance Stores Optimization
- Stores layout and organization
- Issuing and receiving procedures
- Obsolescence management
- Case study: Spare parts rationalization
Day 4: Movement and Transportation
Module 7: Material Flow Optimization
- Internal transportation systems
- Dock management strategies
- Cross-docking techniques
- Packaging considerations
Module 8: Warehouse Management Systems
- WMS features and benefits
- Barcode and RFID applications
- System integration challenges
- Demonstration: WMS software
Day 5: Performance Improvement
Module 9: Lean Principles in Material Handling
- Waste identification and elimination
- Continuous improvement methodologies
- 5S implementation
- Kaizen event planning
Module 10: Safety and Compliance
- Material handling safety protocols
- Regulatory requirements
- Accident prevention strategies
- Final assessment and certification