Last week we discussed the lean process but what does that mean in terms of inventory management? Companies that have adopted the lean process operate by the “less is more” philosophy. Many companies are turning to a more effective inventory system which means no longer stockpiling warehouses with inventory. They realize the importance of being able to quickly adapt to ever changing demands. Anymore, large inventories only create obstacles for business trying to keep up with their customers and the economy.
According to R. Michael Donovan & Co., manufacturers typically have 25-50% excess inventory. What do they mean by “excess inventory”? Excess inventory is any inventory that doesn’t support an objective within the lean process.
Manufacturers need to be careful not to reduce inventory without an actionable goal. Simply liquidating inventory can lead to a magnitude of costly issues including lower productivity, lost sales, and lower profits.
In order to have an effective lean inventory process a company needs to have the right tools in place, changes in their process, right measurement, and the willingness to make the changes permanent throughout the organization.
Reducing inventory to get your business in line with the lean process takes preparation and collaboration across your company. Many companies who have put the lean process in place have seen an improvement of work flow and processes, especially when it comes to inventory.
For additional resources on the lean manufacturing process, visit the IMEC website.
Don't fall into the pit of making your ERP system software too complicated. Then you'll have to hire a team to use it effectively.
An ERP system software is primarily an integrated suite of modules and features that can encompass financial, production, services, human resources, payroll, time entry and CRM (customer relationship management). The software is dependent upon how your company work flow operates, how you would like to set it up and how it can be incorporated efficiently and effectively into the company's environment.
The modules your company purchases is dependent upon what is most important to the company's processes (this goes back to the beginning of our ERP blog series). 
Again, one word of advise as you continue the ERP research buying process ... Keep It Simple Stupid... the old KISS method still applies here. An ERP system too complicated can make your team's life miserable. Then what happens? Your team only uses 35% of the ERP system software you have, which is the national average.
Typically companies are examining a combination of financial management, manufacturing, project management, supply chain management, product life cycle, supplier relationship or customer relationship management (CRM) software ERP modules. Know what your team desires and understand the resources needed from the company (not just the vendor) in undertaking an implementation of any piece of the modular ERP software. There's a commitment required from the company and the vendor and the agreed upon combination equals success.
Industry Specific ERP software can be necessary. I spoke with a CFO from a large asphalt company the other day. They have two types of software they use -- bidding and order/job implementation. Due to the critical element of what can be missed in a bid for a highway or a bridge, there was an ROI (return on investment) for the bidding software they implemented and used habitually. On the other hand, if some customization is necessary, most softwares can handle that but beware that you own the code and that it is in a programmed language that can be integrated to other applications or services.
Next week .... cost!
Which ERP System is right for your business?
If you're frustrated with the way inventory is (or perhaps isn't) being managed, there's a very good chance that you are not alone.
Inventory management is something that we discuss quite a bit on the DataCraft Blog (check out other inventory posts here) because we know it's a common issue among organizations, regardless of their industry.
We'd like to take some time to offer a few white papers that have inventory solutions for inventory accuracy.
Demand Planner
Businesses, regardless of their size or specialization, need to estimate and monitor demand for their goods and services in order to efficiently manage their operations. Reducing uncertainty of demand can significantly help businesses keep inventory and operating costs low while improving customer satisfaction. Download the Demand Planner white paper
Guide to Inventory Basics
Having problems with inventory accuracy? Implementing technologies such as bar coding systems, RFID, and pick-to-light are often assumed to be the solutions to inaccurate inventories. Whether you are planning on implementing additional systems or not you should consider taking care of the basics first.
Download the Inventory Basics white paper
Inventory Turnover Ratio
Inventory management is all about finding the right balance. Every firm has to maintain a certain level of inventory of finished goods so as to be able to meet the requirements of the business.
Download the Inventory Turnover Ratio white paper
Don't let inventory inaccuracy drive you crazy, learn how effective inventory management can increase productivity.
Earlier this week Monica Glenny spoke at the Belvidere Chamber of Commerce Manufacturer's Appreciation Breakfast.
The topic: inventory management. 
Based on the discussion and amount of inquiries after the event, I think it's fair to say that inventory is something that is on everyone's mind.
During Business Clarity sessions, effective inventory management is often brought up by clients, and they're issues aren't isolated to just them.
Inventory is an issue that plagues businesses of all sizes and the same questions typically come up:
- Do we have accurate accounts of all products, materials, or parts?
- What is the physical location of each inventory item?
- What is the cost of producing each unit of product or service?
- Are we ordering appropriate quantities of inventory for future production and sales?
- Do we have any inventory that has been sitting on the shelves for years?
- Are we currently holding too much or too little inventory?
These are all questions that can be answered with the correct work flow process and by understanding inventory ratios
Because it is such a common pain point and has been a hot topic around here lately, we have pulled together some white papers that cover different aspects of inventory management.
Many people use the accounting software in QuickBooks and forget the rest. For the most part, clients know how to use accounts receivable and accounts payable. What is often forgotten or misused in QuickBooks? That would be estimates, sales orders, sales reports and items (products and services you sell).
People misunderstand the importance of using estimates (bids, grants, proposals or quotes) for follow up and profit margin tracking. Sales people or customer service could be entering those estimates directly into QuickBooks. Worried about your employees messing up your software? Security controls can be established so that they can't go anywhere else in the software. Do you know what your profit margin is per job or are you simply making journal entries and "approximating" the profit margins? What was the estimated versus actual revenue and costs? Can you set up your company's selling workflow in the software? You should be able to.
Whether you sell products or services it is vital to set up items in QuickBooks. Why? The more detail you use for item lists the better your reports. Questions can be answered like ... Which item is my best source of income? Which items are my best sellers? Product costs and labor costs should all be set up and tracked in QuickBooks. Pricing? Set up your price levels and use those to your advantage to help control sales profit margins.
The Sales Order tool is excellent for managing partial shipments and sales order fulfillment for inventoried products and their interface to purchase orders, pick lists, and packing slips in QuickBooks.
A full or mini ERP implementation should take full advantage of the financial and business software your company purchased.
For the above metioned QuickBooks functions, it makes a difference which QuickBooks package you have ...
Is QuickBooks right for your company? Compare it to other leading software systems: Download the Software Selection Guide
Unless your company is strictly service based, someone in the business is managing some kind of inventory. Or are they? Do you really know the answers to the following questions:
- Do we have accurate accounts of all products, materials, or parts?
- What is the physical location of each inventory item?
- Are we ordering appropriate quantities of inventory to accommodate future production and sales?
- Do we have any inventory that has been sitting on the shelves for years - "It was a really good buy!"
- How are returned items handled within inventory?
- What inventory items generate the most profit?
Many small to medium sized companies struggle with their inventory tracking software. Some businesses maintain procedures for tracking inventory that are labor intensive. Usually that "labor" is diverted from other revenue-producing activities such as manufacturing, retail sales, and service calls.
What inventory questions do you have? Knowing what information your business needs about its inventory is the first step in inventory management.
Take time to determine your needs; you will drive money to your bottom line with proper inventory management!
Want more information about inventory management? Download the Demand Planner white paper
Managing inventory proves to be a challenging task for many managers and requires knowledge of inventory accounting basics. While the level of inventory varies from business to business, a reliable way to tell your inventory turnover rate is to utilize inventory turnover calculation measures.
The inventory turnover ratio tells you how liquid your inventory is- or how quickly your inventory can be converted into cash.
This ratio measures the number of times (on average) that your inventory is sold during a given period. It also measures how quickly your inventory can be converted into cash.
The inventory turnover ratio is calculated one of two ways. The most common way to calculate the ratio is:
The second and more accurate way to calculate the inventory turnover ratio is:
The second calculation is more accurate because "cost of goods sold" reflects your inventory's book value, and by averaging the inventory, you can reduce seasonal factors that influence the flow of inventory.
Generally, a high inventory turnover ratio means that your products are selling well. But before you get too excited about a high ratio, you need to compare it to the industry standards. If your ratio is higher than other companies in your industry, it could mean that your inventory management systems are ineffective.
Download "Inventory Turnover Ratio" white paper
Yes, knowing the entire financial health of your business is great, but there are times when all you want to know is your company's short term liquidity, and for that the quick ratio or acid-test ratio is where to look.
Here's what it looks like:
The quick ratio will tell you if your company is able to pay its short-term bills using your most liquid assets (cash, money in bank accounts, money market mutual funds, and US Treasury bills)
It's like the current ratio in the sense that it measures your ability to pay short-term debts, but it's more conservative of a measurement because it takes out inventory from your current assets. The inventory is subtracted from the current assets because some businesses can't quickly turn their inventory into cash. The current ratio can sometimes overestimate a company's ability to pay its short-term bills.
For example, if current assets equal $15,000 current inventory equals $6,000 and current liabilities equal $3,000, then quick ratio amounts to: ($15,000 - $6,000)/$3,000 = 3. Since we subtracted current inventory, it means that for every dollar of current liabilities there are three dollars of easily convertible assets.
Ideally, your company's quick ratio should be 1:1. The higher the ratio, the stronger your company is.
Learn more about inventory ratios. Download the Inventory Turnover Ratio white paper.
In the world of accounting, ratios give and invaluable amount of information about your company and it's fiscal well being. Accountants use financial ratio analysis on a regular basis. These analyses help to evaluate the financial performance by comparing financial ratios of a business over various periods of time to other businesses in the same industry.
In his book Financial Analysis Tools and Techniques , financial expert Erich A. Helfert defines ratios analysis as
"the use of a variety of ratios in analyzing the financial performance and condition of a business from various viewpoints such as managers, owners, and creditors.
Get out your financial calculator.
There are three different types of ratios:
Liquidity
Profitability
Solvency
Liquidity
Liquidity ratios measure your business short-term ability to pay bills as they are due and let you know if you have the cash to cover and unexpected expenses. Liquidity ratios compare your most liquid assets (assets that are easily turned into cash) with your short-term liabilities. In general, the greater the ratio of liquid assets to short-term liabilities, the better off your company is. These ratios let you know that your company can pay debts that are owed and still continue to operate normally.
Current Ratios
Acid Test Ratios
Current Cash Debt Coverage
Receivables Turnover
Inventory Turnover
Profitability
Profitability ratios measure the operating success of your company for a specific period of time. They give you a better understanding of how well your company made use of its resources to generate profit.
Profitability Ratios
Profit Margin
Cash Return on sales
Asset Turnover
Return on Assets
Return of Equity
Solvency
Solvency ratios measure how well your business can survive over a long period of time by measuring your income after taxes. Solvency ratios take a look at your past financial statement analysis and let you know if your company can continue to pay its debts now and in the future by looking at your income after taxes. A ratio that is higher that 20% means that your business is financially healthy. The lower your ratio, the greater chance your company will default on its debt obligations.
Solvency Ratios
Debt to Asset
Times Interest Earned
Cash Debt Coverage
All of these ratios, liquidity, profitability, and solvency alike can provide you with useful financial information about your company. If you can get so much information from just looking at one type of ratio, imagine the invaluable knowledge you can gain to keep everything on track and guide your company to success.
