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GSC India

Inventory Process
March 17, 2003
RECEIPT OF MATERIAL INVENTORY FLOW
Receipt of Material
at security.
Enter in IG Register.
Intimate Customs for
Inspection & for Bonding.
Prepare GRN
Physical
Verificatio
n

Reassess
Match
Mismatch
Qualit
y
Check
?
Reject
Clear
Returns to
Vendor
(IGNCMR)
Disputed
Bond
Accepted
Inventory
Bonding
Customs
Rules of the Road
No Over Receipts to be made.
Bonding to be complete before GRN.
Each invoice to have 1 GRN only
No receipt without original documents (exceptions import reassessment,
local lost in transit)
No stock item to be recd as non-stock
GRNs within 3 days of receipt no hold..
Supplier awareness to minimize disputed
cases due to wrong documentation,
description, quantity.
Intimate supplier on rejected quantity debit supplier RMA process
Only Imported & CT3 parts go through Customs, other Local parts do not
go through Customs.

ISSUE OF MATERIAL INVENTORY FLOW
Receive OPSI
Plan
Pick List/JO
Issue Material --
System. & physical
Functiona
l Testing
Clear
Reject
Raise NCMR
NCPR
Manufacturing
Issue Material
Agst NC MR/PR
WIP completion
Rules of the Road
No Issues without GRN & Bin Card
No Issues from Quality; only from Stores
No part kits to line; to be completed before issue.
Material to be issued must be in BOM
For change in BOM - format with back ups & signoff
Cycle count to be done soon after BOM change
No Swap of JOs in line across Products
On line System & Physical depletion
Physical / system transaction in RM only by stores
No material replacement from receiving bay to cater
to NCMR / NCPR rejects
No issues to line till disconnect between physicals and
system resolved; resolution same day
** Material Issued for Job Work, gets moved to Sub-Con Inventory
bucket. Confirmation required monthly.

SHIPMENT INVENTORY FLOW
OPSI Plan
Receipt of PO
Raise
Sales Order.
Sales order issue in
Genesis
Raising of System
Invoice.
Customs approval &
Shipment
Rules of the Road
No Shipment without a Valid PO.
Invoicing only on Completion of FG
JO to be closed only on Completion.
Invoice from Oracle; no Manual Invoicing..
No Shipment of NPI, till TP & ICV finalized.
No time lag in COGS Depletion and AR Booking



INVENTORY LAYOUT CONTROLS
Some Clues
Separate Location for receiving
Separate Location for quality inspection
Separate Location for bonding
Separate Location for quality rejects before GRN
Separate Location for MRBs
No change in location in stores without Stores Managers concurrence
One item, one location in RM


CYCLE COUNT PROCESS INVENTORY
RM Cycle count
All part of Inventory to be grouped as A , B & C class on the basis of Value. ( A & B Constitutes 95% of the total BOM Value arranged in
descending order. C Constitutes the balance 5% of the Value)
Consolidate modality wise A, B & C for all BOMs and prioritize items for count on a daily basis.
Decide on frequency of perpetual count based on number of items for count
(A & B items every 20 days; C items every quarter)
Cross functional team across modality to report mismatches if any, with reasons for the same.
Daily Cycle count report to be published
OWNERSHIP -- Materials and Stores
RIP & MRB Cycle count

RIP & MRB report to be taken out from Oracle for each modality, and physically matched
with stocks lying at RIP & MRB. Report to be published by end of the week.
OWNERSHIP -- RIP : PTLs / BTL s
MRB: Quality & Stores
CYCLE COUNT PROCESS INVENTORY
FG Cycle Count
The FG report is to be taken out from Oracle and matched with Physical FG. Report to be published on a weekly basis.
OWNERSHIP -- PTLs / BTLs

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