Inventory Control - Best Practices and Everything You Need - NetSuite
Inventory Control - Best Practices and Everything You Need - NetSuite
Inventory Control - Best Practices and Everything You Need - NetSuite
Inventory control, also called stock control, is the process of ensuring the right amount of
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supply is available in an organization. With the appropriate internal and production
controls, the practice ensures the company can meet customer demand and delivers
nancial elasticity.
Inventory control enables the maximum amount of pro t from the least amount of
investment in inventory without a ecting customer satisfaction. Done right, it allows
companies to assess their current state concerning assets, account balances and nancial
reports. Inventory control can help avoid problems, such as out-of-stock (stockout) events.
For example, Walmart estimated it missed out on $3 billion worth of sales in 2014 because
its inadequate inventory control procedures led to stockouts.
An integral part of inventory control is supply chain management (SCM), which manages
the ow of raw materials, goods and services to the point where the company or
customers consume the goods. Warehouse management also squarely falls into the arena
of inventory control. This process includes integrating product coding, reorder points and
reports, all product details, inventory lists and counts and methods for selling or storing.
Warehouse management then synchronizes sales and purchases to the stock on hand.
Inventory control practices and policies should apply to more than just nished and raw
goods. The following graphic shows all the things a business might manage using these
practices.
The Reach of Inventory Control: Beyond Finished and Raw Goods
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Spoilage
Dead stock
Excess storage costs
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Cost-e ciency
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Losing loyal customers
Excess stock
Losing track of inventory
Losing goods in the warehouse
Inventory control expert Dr. Pyke advises, “It’s been my observation that the business
world has a weak understanding of inventory management and control. They are trained
shallowly, and sometimes they apply only shallow experience to their practices.
Sometimes, that works out great. In my 30 years of experience, however, I have seen that a
lot of money can be saved by training and managing inventory control in-depth.”
“Like Toyota’s Kanban system for optimizing setups, there are obviously areas that we can
make ow be er. Companies should be proactive in their sequencing system, rather than
reactive—all while making that balance. If you look at the underlying mechanisms during
planning, you can go from there. The system you choose can vary dramatically depending
on the situation and can make all the di erence in your actual performance.”
Chat
Manual: Whether via a ledger or a stock book, manually logging inventory with a pen
and paper is the simplest way to track what comes in and goes out. Small businesses
with few items can get away with using this type of system. This system can be
challenging because it is an actual record that you cannot mine and use for planning
purposes.
Stock Cards: A slightly more complex method uses stock cards, also called bin cards.
A stock card is a table that records the running unit price, sale price and inventory
count of each product. Use individual cards for each product in large warehouses or
stock rooms. The system also tracks purchases, sales, returns and other reasons to
withdraw stock, such as promotional withdrawals. You can include additional notes on
the stock card, such as any problems associated with that item. For a stock card
system to be e ective, consistent updates are critical. You must also record unusual
stock pulls; otherwise, you run the risk of inaccurate data.
Simple Spreadsheets: Many companies, especially small businesses, use
spreadsheets to track inventory. Whether they use Microsoft Excel or something
similar, spreadsheets are a way to start automating and electronically capturing
product data. With consistent updating and basic coding, you can ensure that you
have available current inventory levels and statistics. Businesses quickly customize
these systems to meet their needs. Since everyone who builds a spreadsheet does so
slightly di erently, users will need intimate knowledge of how the sheet works. This
method is also thought of as manual because the only way to automatically update
the spreadsheet system is by adding high-level macros or coding that connects them
with other systems.
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Basic Inventory Software: Simple inventory software is usually low cost and
targeted to small and medium-sized businesses. This simple automation is often
cloud-based and ties into your point of sale software, so it can generate real-time,
automatic stock updates. You can also incorporate analytics and reporting and run
cost comparisons, create reorders, identify best and worst-selling products and drill
down to order details or customer pa erns. Some simple inventory management
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software systems can scale to more complex functionality as your business grows.
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Some businesses prefer to stick to the simple systems of keeping track of inventory. Other
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companies plan for growth and scaling. You could also track inventory with:
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The challenges of the periodic system are especially apparent when performing a physical
inventory count. Most normal business activities must be suspended during this time
because it requires signi cant manual labor. Many companies hire additional sta and try
to perform this outside of regular business hours, such as during a night shift. This type of
system incurs more fraud because there is nothing tracking inventory between physical
counts, reducing accountability between inventories, and because it is more challenging to
determine where any inventory discrepancies occurred.
The challenges of this type of system occur when you use it without also performing
physical inventories. In other words, the recorded inventory may not accurately re ect
what is physically in-stock as time goes by, never mind accounting for drop shipments or
inventory on order. You must account for breakage, stolen goods and loss to ensure the
system is accurate. Further, errors and improperly scanned items a ect the inventory
records. You can handle this mathematically by applying corrections that mostly account
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for these things. Experts agree, though, that even though physical inventories are not
common,
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perpetual system. You can integrate these types of systems with supply-chain automation
to make quicker decisions informed by data.
Barcodes
Barcodes can be part of either a perpetual or periodic inventory system. Some may
consider the barcodes part of an inventory management system, but in truth, this is
equipment that falls under your existing inventory management system. A barcode is
essentially a li le picture with text or numbers that gets put on each stock item. The text or
numbers store a large amount of information. A scanner reads that information and
transfers it to a database, which tracks the parts and their locations. The system performs
scans when the new inventory arrives and when it is issued out. Barcodes have a rapid
return on investment (ROI) by lowering operating expenses once implemented, even for
small businesses
(h ps://pdfs.semanticscholar.org/9539/771945831a5a546fc81209eed858cb054d31.pdf).
RFID tags are an e ective way to protect high-value items and products that require
additional security compliance, such as pharmaceuticals. Active tags are the best course in
businesses where inventory security has been an issue.
Remote Tag Reading: The reading range for passive tags is approximately 40 feet,
and the range for active tags is 300 feet.
Simultaneous Tag Reading: The system can read several tags simultaneously so
that it can check in an entire pallet of products at once.
Unique Tag Codes: To track unique products, not just one type of product, you can
give tags unique identi cation codes.
Constant Updates: Without having to update the physical tag on the item, you can
send it updates such as warehouse location via your active tag or by keeping the
passive tag system activated.
If you are considering using RFID tags, they have become cheaper in recent years. Experts
say the best use of RFID tags is to place them at high-risk points close to your stock, such
as at exits. Finally, for products with a limited shelf life, an RFID system can provide
information to ensure quality control, such as when they were brought in and their
expiration dates(if relevant).
A recent trend among small businesses is the use of QR codes, which are like barcodes,
but you don’t need to buy expensive equipment to read them. You can install an app on a
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smartphone that reads QR codes. They also carry more information than a barcode
because of their matrix-like pa erns. QR codes are not active systems like active RFID tags
and not nearly as expensive.
Methods of Inventory Control
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Inventory control methods are the ways you use your business’s strengths and
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relationships, your expertise, formulas and forecasts to determine how much supply you
keep, sell, store and order. E ective inventory control balances controlling costs and
meeting customer demands.
A company’s days of inventory outstanding (DIO) measures how many days a company
holds stock before selling it. The DIO is an e ciency measure because inventory ties up
funds. The lower the DIO the be er, especially for a small business. DIO scores have
increased in the past ve years by 8.3% (h ps://www.dol.gov/general/topic/statistics),
meaning that companies have poorer inventory control practices. Additionally, there is a
need to increase warehouse space, which means…
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The most e ective inventory control methodology can vary between companies.
Whichever methodology you choose, it should be clear to employees and have well-
de ned policies and procedures. If you use software with your methodology, look at
systems that boast the key features your company needs, not just a one-size- ts-all
package. Organizational control starts with labeling items, whether via SKUs or a more
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complex system. Quality control requires having quality standards and policy for sta to
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FIFO and LIFO: These are methods of placing value on the products. LIFO assumes
that the goods last added to the inventory are the rst goods to be sold, while FIFO
assumes that the goods rst added to the inventory will be the rst sold.
Min-Max Inventory Control: This theory sets minimum and maximum levels of
stock to maintain speci c items in your inventory. So when you get to the minimum
level of stock, order only enough to reach the maximum level set. Critics of this
approach say that you may end up with either too many or too few products.
JIT Inventory: The just-in-time (JIT) inventory management strategy lines up the
raw material order from suppliers with the production schedule. You decrease waste
in the form of inventory cost because the goods are onsite only as needed. JIT can be
a step in Lean manufacturing by slightly requiring JIT to incorporate what the
customer wants in each product manufactured. The risk with this method is running
out of stock due to ine cient suppliers, but supplier relationship management can
somewhat mitigate this risk.
Two- or Three-Bin System: A two- or three-bin system involves two containers of
the same stock item. When one container becomes empty, you use the second
container (the backup), which then identi es the reorder point (ROP). The ROP is
when inventory gets down to a level that initiates stock replacement activities. The
problem with a method this basic is evident in situations where there are big or fast
orders. You may never be exactly sure how much product is in stock at a given time,
so you may not be able to predict whether you can ful ll a large order or quick,
successive orders.
Fixed Order Quantity: In a xed order quantity rule, you may only order a speci c
amount of an item at one time. With this rule in place, reorder mistakes, storage
space issues and unnecessary expenses are kept to a minimum. You may link xed
order quantities to automatic ROPs. Chat
Fixed Period Ordering: In a xed period ordering rule, you link the replenishment of
speci c items to a particular interval. In this case, the order quantity is always di erent
to compensate for customer demand.
Vendor-Managed Inventory (VMI): In this method, it’s often the sales
representative that manages the stock on speci c products, noticing and ordering
what needs replenishment. For example, a beverage company representative who
performs deliveries reviews the stock and space available for their products in the
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store and replenishes it themselves.
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signal you to order more. Par levels vary by product, relative sales rates and the time
to restock and require research and sound decision-making. Par levels change over
time and must be reset at regular intervals. On the positive side, having minimum
levels makes your business more e cient and exible. When new products hit the
market, you can purchase them because your funds are not completely tied up in
existing inventory.
Further, storage costs are lower, and if your business moves fast, having only the
minimum levels of stock may be more suitable. Some challenges you may face
include possibly running out of stock, when ordering the minimum could be more
expensive and the variability of how well your suppliers can deliver products quickly
and e ciently. You should also have a safety stock alongside your minimum
inventory. Safety stock is the stock you keep in excess in case there are delays in
delivery. You use this stock only in case of emergency.
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Bundling: Combining goods or services to o er the customer extra value for one
cost is called bundling. In inventory control and management practice, bundling is Chat
a
way to move aging inventory. For example, you include a surprise free gift or o er a
reduced price on another item based on a purchase. These techniques also improve
your customers’ experience.
Rolling Inventory: When inventory is rolling, instead of storing goods inside a
warehouse, managers leave it in the truck trailer and store that trailer in the
warehouse parking lot. A driver can hook up the trailer when the stock is needed and
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drive it to the retail store. Warehouse employees never touch the inventory.
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or supplier directly ships its products to customers on behalf of the retailer. The
retailer never has the product in stock and never handles or sees the product. These
businesses mostly work via internet sales.
Consignment Inventory: This business arrangement occurs when a company gives
its goods to another company or storefront before they pay for them. The storefront
or company pays for the products once it sells them, for an agreed upon percentage
of the sale price. This arrangement can be an excellent situation for small businesses
that are selling the products because their cost of ownership is minimal.
Backordering: When a company decides to take orders and payments for products
that are not in stock, they are taking backorders. For a small number of items (one or
two), it is easy to process the order and inform your customer with a forecast of when
you will ful ll it. Further, the higher the value of the item, the more patient your
customers will be with backorders. Problems mount, however, when the backordered
products start to multiply. It is not recommended that small businesses whose
products are generally stocked on-site mix with many backorders. Positive reasons to
o er backorders include increasing cash ow, adding some exibility for small
businesses not capable of handling the logistics and lower holding and overstock
costs. Challenges of backordering include possibly disappointing customers, longer
ful llment intervals and other logistical requirements.
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ABC Analysis: This method of supply chain forecasting divides all on-hand
inventory into three distinct groups. “A” items are those of high value and low sales
frequency. The budgetary impact of these items is signi cant, but their sales are not
predictable. “B” items are those of moderate value and moderate sales frequency. “C”
items are those of low value and high sales frequency. These items require less
oversight due to their lessened monetary impact and constant turnover. Using these
delineations for inventory helps you prioritize by separating out products that need
more a ention than others. Forecasting done with ABC analyses calculates the
number of stock available based on this delineation. Additionally, storage and Chat
packing locations can be set up to re ect these delineations.
Reorder Point (ROP) Formula: The ROP formula mathematically tells you the right
time to order or produce more stock. Using existing information, calculate the sum of
your lead time demand and safety stock. You may need to know the reorder lead
time alongside this formula, which is the time between placing an order and when
you receive it. You must account for the lead time when calculating order timing. The
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formula for reorder point is:
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Let’s say that Ava has to calculate the ROP for the liquid bandages her company Chat
manufactures in its facility. She calculates the safety stock (SS) for this product at 50 units.
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She then calculates the Lead Time Demand (LTD) for that product.
Her manufacturing department uses 20 units of raw materials per day, and it takes about
ve days for a reorder of those materials to arrive.
Chat
If stock for liquid bandages falls below 150 units, then Ava must place a reorder.
“Inventory management gets complicated very quickly, explains Dr. Pyke. “For example, a
reorder point model has a trigger. So, the order xed quantity is hopefully set up in a way
that optimizes the trade-o s involved (i.e. too much versus not enough). When I am
helping a business, this is where I usually start their training. Moreover, problems often
come in manufacturing when there are lags between the startups and process
changeovers—for instance, an ice cream manufacturer changing over from chocolate to
vanilla versus vanilla to chocolate. In the la er example, going from vanilla to chocolate,
there are fewer complications and problems. Also, chocolate covers over a multitude of
sins! However, when you go from the more complex (chocolate in this scenario) to the less
complex (vanilla) process, it can take longer and add unnecessary layers of complexity.” Chat
Economic Order Quantity (EOQ): The EOQ determines the optimal amount of
inventory you should buy or produce to make the costs of ordering and storing
minimal. This formula is useful for when the demand, ordering and holding costs are
consistent over time. You can modify the EOQ formula to compensate for di erent
production levels or order intervals.
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Let’s say that Ava wants to know the optimal number of size 12 glass bo les she wants to
have in-stock for production. They are quite costly to purchase and store, so she must
calculate the EOQ. Ava’s production team uses 1,000 size 12 glass bo les annually. It costs
her rm about $3 per year to hold that bo le in inventory, and the xed cost to place an Chat
order is $5. Therefore,
The ideal order size to minimize costs and meet customer demand is a li le more than 33
size 12 glass bo les. Now that you have the ideal quantity, you can also use the ROP
formula to determine the perfect timing to order these size 12 glass bo les.
Chat
Batch Control: To control inventory you are producing, you can execute batch
control. This method produces goods in batches sized to ensure that the right
amounts of components are available to produce the required number of the
nished product. Batch control is especially useful in concert with methodologies
such as Lean manufacturing and just-in-time. Batch control procedures save money
and resources.
Third Party Logistics (3PL): Some companies outsource portions of their supply
chain, such as in their warehouse, distribution or ful llment services. Outsourcing
may occur at certain times of the year, such as during the holidays. 3PLs turn over
employees constantly, especially when they only hire them seasonally. These
inexperienced employees can account for a signi cant amount of lost or missing
inventory.
Bulk Ordering and Shipping: One way to manage costs is to order items that you
consider evergreen in bulk. You can also ship evergreen items in bulk at a discount.
Companies lay out more money in advance, but since the items sell quickly and
steadily, the risk is low. Bulk stock is easier to manage because of the product
consistency, making the management costs lower. Manufacturers o er a discount
when ordering multiples of the same product, making the products cheaper. This
option may be suitable where the demand is di cult to predict. However, bulk
ordering means higher storage costs, is challenging for perishable goods, can lead to
obsolete stock and ties up capital.
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Un nished stock, also called work-in-progress (WIP), costs you in storage space but is
often bene cial. You can add an extra level of protection to your production with
un nished stock. For example, if you have a machine in the middle of a process that is at
risk of breaking down, you can pull the un nished stock to bypass that part of the process.
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Keep extra nished stock around when you identify a product’s demand or when you are
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How much consumable product stock you should keep around also depends on the
reliability of your suppliers. If the demand for those products is well-known and steady,
you may want to keep extra. Further, if you expect price rises or get a signi cant discount
for bulk buying, having additional consumable stock is acceptable.
If you are developing new SOPs, clearly de ne policies and processes, and ask sta
members (especially new ones) to review them for understandability. Additional tips for
Chat
inventory control policies include:
Purchase Orders: Before processing an order, clients or sales sta submit purchase
orders. These documents should be completed and signed by the customer,
ensuring that all details are accurate.
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Order Receipts: Policies around an order receipt should re ect the set of checks you
perform upon delivery of a product. These checks should kick o invoicing and
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include the shipment tracking numbers and receipt paperwork.
Invoicing Processes: Templates are ideal to use for invoicing, especially if your
software automatically creates them. Policies around invoicing should ensure the
purchase order number, invoice date and include all the required payment details.
Software: If your customer base is large or growing, consider investing in invoicing
software. Create policies that help support the development of a template, and
ensure the software tracks and archives all transactions. Software can also make
generating unpaid invoice reports more e cient and straightforward.
Past Due Payments: Inform all customers of your late payment or nonpayment
policy. Be exible, but ensure that these documents re ect the consequences. For
example, explain grace periods and procedures about who follows up on tardy
invoicing and what leeway they have so customers can make their own decisions
about paying an invoice late.
Some companies are so worried about not having enough inventory, they overstock,
which costs them more than just the price of goods. Since they tie up their capital, they
must store their products at a cost, and they can become damaged or depreciated. Break
down your inventory into three basic categories:
Chat
Safety stock
Replenishment
Excess and obsolete
Another KPI is sell-through-rate (STR), which helps retain customers. Use the STR as a
metric to identify how long a product is in stock, if you need to reprice it and when to
reorder. This metric is often compared to the inventory turnover rate, which has a longer
period to calculate (often a full year). The sell-through-rate KPI compares stock received
through a supplier to determine how much you sell monthly:
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Average inventory is a KPI that helps you understand how many products you are storing
over speci ed periods:
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Finally, the ll rate is a KPI that tells you how well you ful lled your orders for single
deliveries or for deliveries over a given time. This KPI is also called line item ll rate (LIFR),
with the term “line” referring to the line on an order or manifest. The formula for LIFR is:
A ful lled order is complete when it is at 100%. For example, Jack Heinz orders four
products:
Chat
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This company shipped lines one through three (the seamless carbon steel pipes, copper
pipes and plastic trench drain with grates) on May 20, 2019. When the company ran the
LIFR, it was noted as 75%, because there were four line items, of which only three were
lled:
The company shipped out the 90-degree threaded ing on line four on May 24, 2019,
bringing the LIFR to 100%. However, if your metric focuses on customer satisfaction based
on ful lling orders immediately, keep the metric for only the initial rate. The initial LIFR is
75% and undoubtedly provides more information than the nal LIFR.
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You can also calculate ll rates by case and value. When you expedite items outside the
total shipment, you cannot count those non-expedited items as having been misses, and
you should factor out the expedited items. In other words, your primary concern should be
how your business lls orders regularly, not during exceptions. For more KPIs to track, see
“3 Critical Inventory Accounting Metrics You Should Be Tracking.”
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According to Dr. Pyke, one software solution doesn’t t all organizations. He says, “there
are systems that integrate with existing ERP (enterprise resource planning) systems. Some
organizations have developed their own systems, taking their best thinking, and
developing what they need exactly in-house. When I consult, I often help small businesses
develop their own spreadsheets to start. One of the companies I advise is a large software
company, and their software is excellent and can do major things for their company. These
systems do exist for smaller companies, but there are also inexpensive options that can do
just as good a job.”
Some software systems will integrate with existing systems, but some will not. It’s
critical to decide whether you need this integration or if you will build in the additional
costs to replace the software. For more information on software integration, see “The
Bene ts of Integrating Your Inventory Software with Your Accounting and Back-O ce
Processes” (/portal/resource/articles/inventory-management-software.shtml).
Further, let us assume that your business has a trajectory of massive growth within
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the next ve years. In that case, select software that can scale.
3. What can I pay for software?
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Software systems that target inventory control can di er wildly in cost. Good
salespeople can quote a price based on your requirements. In that bo om line,
include any other software that needs to change to accommodate the new purchase
and the cost to transition in sta time. Calculate the return on investment (ROI) for
every solution you review and how long it will take to recoup that investment. For
more information on lowering your costs, see “Lower Your Costs by Using Inventory
Tracking Software.” (/portal/resource/articles/inventory-management/lower-your-
costs-by-using-inventory-tracking-software.shtml)
4. What does software mean for sta ng?
Determine if your current sta can adapt to vast changes in how you do business.
Then decide if you need to hire new sta with di erent skill sets, reassign or retrain
your current team. For example, if you employ many low-skilled workers to count
inventory, you may not need them with a perpetual inventory system. Further, they
may not be able to help you set up your new software or troubleshoot it after
installation. You may need to hire a sta member with technical software skills,
depending on the complexity of what you buy. If you can reassign loyal sta
members to other jobs or train them for the software, excellent. Otherwise, consider
what your business needs are rst.
Increase in pro ts
Never have stockouts
Barcodes and label track inventory
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No more inventory write-o s
Quick and e cient auditing
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Saved time
More system exibility
Quick information retrieval
Built-in analytics for decision-making
To get started, look for the software with features that support your business’s needs and
future.
When looking for new inventory control software, consider these features:
“Blockchain in the supply chain is also up-and-coming. You do not need blockchain to be
valuable, but the visibility to what is out there will improve. Over time, it will be interesting
to see what is real and what is hype, but it all will have an impact, regardless. My advice is
for businesses to sit on the sidelines for a bit and see what happens. Eventually,
companies will be able to use it for improvements in inventory management.”
For more information on features you should look for to support your business, see “3 Key
Features to Look for When Selecting Inventory Management Software.”
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Once you have inventory control software set up, follow these tips:
Use platforms that talk to each other or have everything under the same system.
Treat each item in your inventory di erently; each SKU is di erent for a reason.
Ensure your supplies are above board by using the available data.
Use mobile devices when possible.
Slot your inventory.
Perform cycle counts and update the data in your system.
Link all transactions to your software.
You should also ensure that you do not purchase something too complicated for what Chat
your company needs and that the software is worth the cost. If you don’t, it’s not just a
waste of money, but you could end up needlessly frustrated. If your software comes with
analytics capacity, though, make sure you perform the measurement.
If you bought or are looking to purchase inventory control software, use it to perform the
following calculations:
What products are selling and not selling
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Total inventory costs
Inventory trends and sales data
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The inventory budget
For more information on choosing the right inventory management system, see
“Choosing the Right Inventory Management System.”
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You should t expensive, high-end items such as computers and electronics with RFID
tags that can add security. An alarm will sound if they are removed. Be sure to secure
deliveries after their arrival. Before you log items into your system is a prime time for them
to get lost or stolen. Dispose of any additional packing materials, so thieves do not get the
idea that a delivery just took place. If possible, install closed-circuit television (CCTV), also
called video surveillance, in your parking lots and other vulnerable locations to de ect
potential theft.
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An outside threat isn’t the only security concern you should have. Sta can steal, too. Train
your team on the security systems in place and policies that address theft and its
discipline. Many people are unaware of the toll theft takes on a business, including the
costs of sta turnover and job security. So, train your sta to understand the true e ects of
stealing.
By se ing up procedures that prevent theft, you can stave it o before it occurs. For
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example, sta who oversee stock should not also monitor the company’s nancial records.
Restrict
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require access to every portion of your warehouse or every supply cupboard. Assign sta
responsible for auditing to assist other sta with their supply needs. Regularly reassign
sta to stock control to prevent collusion. Finally, consider if you’re using the functions in
existing software to their best ability. The National Retail Federation nds that internal theft
is down a minimum of 11% in businesses that use inventory management software
(h ps://nrf.com/research/member-submi ed/inventory-management-retailers-how-set-
manage-and-optimize-winning).
Learn more about how you can use NetSuite to manage inventory
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automatically, reduce handling costs and increase cash ow.
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In uence a buyer's decision making process Synchronize sales, marketing, customer
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