A Journey of Material from Stores to Shop Floor

The material movement process in a store, from the receiving gate to issuance, is a crucial aspect of inventory management and warehouse operations. Here's an overview of the typical steps involved in this process:

Steps of Material Exchange Journey Starting from Gate Entry in Plant Premises to Material Issuance to Shop Floor Area:

Receiving at the Gate:

• When raw materials or products arrive at the facility, they are usually inspected at the receiving gate.
• Documentation, such as packing lists and invoices, is checked for accuracy.
• Materials are visually inspected for any damage or discrepancies.

Unloading and Inspection:

• Materials are then unloaded from the transport vehicles, such as trucks or containers.
• A physical inspection is carried out to verify the quantity and quality of the received materials.
• Any discrepancies or damage are documented, and the appropriate action is taken, such as contacting the supplier or initiating a return.

Material Receipt: 

• After successful inspection, materials are officially received into the warehouse/store.
• The received materials are assigned a unique identification number or barcode for tracking purposes.
• Details of the received materials are recorded in the inventory management system.

Storage:

• Received materials are then moved to their designated storage locations within the warehouse.
• These storage locations are often based on factors like material type, size, weight, and shelf life.
• Proper labelling and shelving are essential to facilitate easy retrieval.

Inventory Update:

• The inventory management system is updated to reflect the new stock levels.
• This includes recording the quantity received, date of receipt, and any relevant details.

Material Handling and Storage:

• Warehouse staff use forklifts, pallet jacks, or other equipment to move materials to their designated storage locations.
• Materials are often organized using the "first-in, first-out" (FIFO) or "last-in, first-out" (LIFO) method, depending on the material's characteristics and requirements.

Inventory Monitoring:

• Warehouse management software or systems continuously monitor stock levels.
• Alerts are generated for low stock levels or materials nearing their expiration dates.

Order Preparation:

• When there is a need for materials, such as for production or order fulfillment, a requisition or work order is generated.
• The inventory management system helps identify the location of the required materials within the warehouse.

Material Retrieval:

• Warehouse personnel locate and retrieve the requested materials from their designated storage locations.
• Barcoding and scanning systems may be used to ensure accurate retrieval.

Issuance:

• The materials are issued for use in production, assembly, or shipping.
• The issuance process is documented, and stock levels are updated in real-time.

Inventory Reconciliation:

• Regular physical counts and reconciliations are conducted to ensure that the inventory records match the actual stock levels.
• Discrepancies are investigated and corrected.

Reporting and Documentation:

• Detailed records are maintained for all material movements, receipts, issuances, and adjustments.
• This documentation is essential for compliance, audits, and performance analysis.

Returns and Damaged Goods:

• If materials are found to be damaged or defective during the issuance process, they are processed for returns or disposal, and proper documentation is maintained.

Other Key functions and features of a raw material store 

• Organization: 

Raw materials are typically organized in a systematic and orderly manner to facilitate easy access and retrieval. They may be categorized, labeled, and stored on racks, shelves, or pallets.

• Inventory Management: 

Sophisticated inventory management systems may be employed to track the quantity, location, and status of raw materials. This helps ensure that materials are available when needed for production.

• Security: 

Raw material stores often have security measures in place to protect against theft, damage, or unauthorized access. This can include surveillance cameras, access controls, and secure storage areas.

• Environmental Control:

Depending on the nature of the materials, environmental controls such as temperature and humidity regulation may be necessary to prevent degradation or spoilage.

• Safety Standards:

Safety measures, including proper handling and storage of hazardous materials, are critical to ensure the safety of personnel and compliance with regulations.

• Just-in-Time (JIT) Inventory:

Some manufacturing operations implement JIT principles, which aim to minimize inventory levels by ensuring that raw materials are delivered just in time for production, reducing storage requirements.

• Quality Control:

Materials in the raw material store may undergo periodic quality checks to verify their suitability for use in production.

• Space Optimization:

Efficient space utilization is essential to maximize storage capacity while minimizing wasted space.

• Material Handling Equipment:

Depending on the size and weight of materials, equipment such as forklifts or conveyors may be used for material handling within the store.

The raw material store plays a crucial role in ensuring the uninterrupted flow of materials to the production line, minimizing production delays, and ultimately contributing to the overall efficiency and effectiveness of the manufacturing process. Proper management of this area is essential for maintaining product quality, meeting production schedules, and controlling costs.