Inventory is important parts of business. Its impossible to be ZERO but its not good when we are keeping too much. Its like Cholesterol inside of BLOOD, good in some amount. Inventory is About COST! So it should be Effective and Accurate!

1. TuLIPBerhasil "Cycle Counting"
of
@Mitratama, +62 816 729 301
RODAMAS Group wsukmoro@gmail.com
08 September 2011
21DD9DD1
Inventory Record Accuracy
Partisipasi 100%
ACCURACY
Is NOT
Always absolute.
Inventory Record Accuracy
@WawangSukmoro 1

2. TuLIPBerhasil "Cycle Counting"
WHAT are we
GOING to MAKE?
WHAT does it WHAT do we
take to MAKE? HAVE?
WHAT do we
HAVE to GET? Physical count
within RANGE
WHEN?
=
An Accurate
Record.
Inventory Record Accuracy
Inventory Record Accuracy
@WawangSukmoro 2

3. TuLIPBerhasil "Cycle Counting"
Cycle Counting Status:
RECORD ACCURACY =
No. Record Counting Tolerance Hit Miss
TOTAL accurate records 1 100 94 +2% X
X 100% Inventory
TOTAL records checked
2 100 95 +5% X
3
4
100
100
96
98
+2%
+2% X
X
Record
5 100 99 +2% X y
Accuracy
6 100 100 +2% X
7 100 103 +5% X
8 100 104 +5% X
= 6 / 10
9 100 105 +2% X = 60%
10 100 106 +5% X
TOTAL 1,000 1,000 6 4
TOLERANCE? TOLERANCE?
5%
CLASS Quantity Value Tolerance
or
2%
A 20 80 +0%
B 30 15 +2%
C 50 5 +5%
Inventory Record Accuracy Inventory Record Accuracy Phase
PROGRESS Phase #3:
100%
100%
Cycle Counting
Phase #2:
Develop Initial
50%
50% Balance
40%
Phase #1:
Design & Preparation
TIME TIME
Inventory Record Accuracy
@WawangSukmoro 3

4. TuLIPBerhasil "Cycle Counting"
PHASE #1: Design & Preparation (1/7) PHASE #1: Design & Preparation (1/7)
+
ON HAND +
STOCK
IN ‐ OUT IN ‐ OUT
(record)
( d) (fisik)
(fi ik)
DESIGN PROCESS TRANSACTION DESIGN PROCESS TRANSACTION
PHASE #1: Design & Preparation (1/7) PHASE #1: Design & Preparation (2/7)
In transit RM ADDRESS = PWF‐Sc01‐WIP
On hand
Stock Negara Department P = Production
WIP RM + FGS
WIP RM + FGS Kota Section W WET
W = WET
Kode Pos Working Station F = Filling
FGS Jalan Rack Sc = Sachet
In transit FGS Gedung Katagory WIP
Scrap + Losses
DESIGN PROCESS TRANSACTION MEASURE STARTING POINT
PHASE #1: Design & Preparation (2/7) PHASE #1: Design & Preparation (3/7)
Address: PWF‐Sc01‐WIP
People
Description: ______________________________
Item No.: ______________________________
Unit:
QTY:
______________________________
QTY: ____________________________________
____________________________________
System
Ref. No.: ______________________________ Physical
Tanggal: Tanda Tangan:
MEASURE STARTING POINT PROVIDE TOOLS
Inventory Record Accuracy
@WawangSukmoro 4

5. TuLIPBerhasil "Cycle Counting"
PHASE #1: Design & Preparation (4/7) PHASE #1: Design & Preparation (4/7)
Pemetaan In Transit
Data per Area On Going
Format WIP
Rekonsiliasi Reject
Pelaporan Losses
POLICY & PROCEDURE POLICY & PROCEDURE
PHASE #1: Design & Preparation (5/7) PHASE #1: Design & Preparation (6/7)
Counter
Leader on Area (PIC)
Rekonsiliasi
Reporting
Verifikasi
Summary Closing
Sign-off
TRAINNING ASSIGN RESPONSIBILITIES
PHASE #1: Design & Preparation (7/7) PHASE #2: Develop Initial balance
CLASS Quantity Value Tolerance
A 20 80 +0% Purchase Sales
+ ‐
B 30 15 +2%
C 50 5 +5% STOCK
‐ +
A = 100% Counted = Weekly
B = Random 50% Counted = Be‐Weekly
C = Random 50% Counted = Monthly WIP
IMPLEMENTATION TEORI, PERHITUNGAN, FISIK
Inventory Record Accuracy
@WawangSukmoro 5

6. TuLIPBerhasil "Cycle Counting"
PHASE #3: Cycle Counting (1/2) PHASE #3: Cycle Counting (2/2)
Authorized Person
Leader = Accounting Counted Twice
PIC = Supervisor
Counting = ???
Clear Instruction
Reporting = Admin Floor
Reconciliation = PPIC
Closing = Accounting
CONTROL ‘TEAM’ ON GOING PROGRAM
Man Measurement
I
Frequency
R
A WIP Production
Order Receiving
Method
h d Machine
M hi Materials
l
Scrap
Type of Error
Fishbone
Diagram Pareto Analysis
Frequency
Frequency
Salah label Salah label
Salah transaksi • Training
WIP WIP • Orang
Salah hitungg
• Hilang
Salah lokasi • Tercampur
Type of Error Type of Error
Pareto Analysis Pareto Analysis
Inventory Record Accuracy
@WawangSukmoro 6

7. TuLIPBerhasil "Cycle Counting"
BOM Accuracy
Scrap Records RECORD ACCURACY =
Pengantian Materials
TOTAL accurate records
Alokasi pemakaian X 100%
TOTAL records checked
Pelaporan Produksi
On Going Usage
g g
Ketepatan Dokumentasi
< 90% ~ Kurang
90 < Cukup < 95
96 < Baik < 97
97 < Puas < 98
98 < EXCELLENCE!
Inventory Record Accuracy
Inventory Record Accuracy
@WawangSukmoro 7