TuLIPBerhasil"CycleCounting"

of

@Mitratama, RODAMASGroup 08September2011

InventoryRecordAccuracy

+62816729301 wsukmoro@gmail.com 21DD9DD1

Partisipasi 100%

ACCURACY IsNOT Alwaysabsolute.

InventoryRecordAccuracy @WawangSukmoro

TuLIPBerhasil"CycleCounting"

WHAT are we GOING to MAKE?

WHAT does it take to MAKE?

WHAT do we HAVE?

WHAT do we HAVE to GET? WHEN?

Physicalcount withinRANGE = AnAccurate Record.

InventoryRecordAccuracy

InventoryRecordAccuracy @WawangSukmoro

TuLIPBerhasil"CycleCounting"

RECORDACCURACY=
TOTAL accurate records X100% TOTAL records checked

CycleCountingStatus:
No.
1 2 3 4 5 6 7 8 9 10 TOTAL

Record
100 100 100 100 100 100 100 100 100 100 1,000

Counting
94 95 96 98 99 100 103 104 105 106 1,000

Tolerance
+2% +5% +2% +2% +2% +2% +5% +5% +2% +5%

Hit

Miss X

X X X X X X X X X 6 4

Inventory Record y Accuracy =6/10 =60%

TOLERANCE?
CLASS Quantity Value Tolerance

TOLERANCE?

5% 2%
or

A B C

20 30 50

80 15 5

+0% +2% +5%

InventoryRecordAccuracy PROGRESS
100%

InventoryRecordAccuracyPhase
100%

Phase#3: CycleCounting Phase#2: DevelopInitial Balance Phase#1: Design&Preparation

50%

50%

40%

TIME

TIME

InventoryRecordAccuracy @WawangSukmoro

TuLIPBerhasil"CycleCounting"

PHASE#1:Design&Preparation(1/7)

PHASE#1:Design&Preparation(1/7)

IN

ONHAND (record) ( d)

OUT

IN

STOCK (fisik) (fi ik)

OUT

DESIGNPROCESSTRANSACTION

DESIGNPROCESSTRANSACTION

PHASE#1:Design&Preparation(1/7)

PHASE#1:Design&Preparation(2/7)

IntransitRM Onhand Stock WIPRM+FGS WIP RM + FGS FGS IntransitFGS Scrap+Losses DESIGNPROCESSTRANSACTION

ADDRESS=PWFSc01WIP
Negara Kota Kode Pos Jalan Gedung Department Section WorkingStation Rack Katagory P=Production W WET W =WET F=Filling Sc=Sachet WIP

MEASURESTARTINGPOINT

PHASE#1:Design&Preparation(2/7)
Address:PWFSc01WIP Description: ______________________________ ItemNo.: ______________________________

PHASE#1:Design&Preparation(3/7)

Unit: ______________________________ QTY: QTY: ____________________________________ ____________________________________ Ref.No.: Tanggal: ______________________________ Tanda Tangan:

People System Physical

PROVIDETOOLS

MEASURESTARTINGPOINT

InventoryRecordAccuracy @WawangSukmoro

TuLIPBerhasil"CycleCounting"

PHASE#1:Design&Preparation(4/7)

PHASE#1:Design&Preparation(4/7)

Pemetaan Data per Area Format Rekonsiliasi Pelaporan

POLICY&PROCEDURE

In Transit On Going WIP Reject Losses

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

ASSIGNRESPONSIBILITIES

PHASE#1:Design&Preparation(7/7)
CLASS Quantity Value Tolerance

PHASE#2:DevelopInitialbalance
Purchase

A B C

20 30 50

80 15 5

+0% +2% +5%

Sales

STOCK
+

A=100%Counted=Weekly B=Random50%Counted=BeWeekly C=Random50%Counted=Monthly

WIP

IMPLEMENTATION

TEORI,PERHITUNGAN,FISIK

InventoryRecordAccuracy @WawangSukmoro

TuLIPBerhasil"CycleCounting"

PHASE#3:CycleCounting(1/2)

PHASE#3:CycleCounting(2/2)

Leader = Accounting PIC = Supervisor Counting = ??? Reporting = Admin Floor Reconciliation = PPIC Closing = Accounting

Authorized Person Counted Twice Clear Instruction

CONTROLTEAM

ONGOINGPROGRAM

Man

Measurement
Frequency

I R A
Method h d Machine M hi Materials l

WIP

Production Order

Receiving Scrap

Fishbone Diagram

TypeofError

ParetoAnalysis

Frequency

WIP

Salah label Salah transaksi g Salah hitung Salah lokasi

TypeofError

Frequency

Salah label WIP

Training Orang Hilang Tercampur

TypeofError

ParetoAnalysis

ParetoAnalysis

InventoryRecordAccuracy @WawangSukmoro

TuLIPBerhasil"CycleCounting"

BOM Accuracy Scrap Records Pengantian Materials Alokasi pemakaian Pelaporan Produksi g g On Going Usage

RECORDACCURACY=
TOTAL accurate records X100% TOTAL records checked

Ketepatan Dokumentasi

< 90% ~ Kurang 90 < Cukup < 95 96 < Baik < 97 97 < Puas < 98 98 < EXCELLENCE!

InventoryRecordAccuracy

InventoryRecordAccuracy @WawangSukmoro