warehouse management

WAREHOUSE MANAGEMENT – ONE TERM (13 WEEKS)

1. Course Description

This course introduces learners to the principles and practices of Warehouse Management within a supply chain environment. It focuses on warehouse functions, inventory control, storage systems, materials handling, documentation, technology, risk management, and performance evaluation. Learners develop practical skills for efficient handling, storage, safeguarding and issuing of goods while applying safety and operational standards required in modern warehouse operations.

Suitable for students in Supply Chain Management, Procurement, Logistics and related TVET programs.

 

2. Course Duration

13 Weeks (One Academic Term)

 

3. Course Learning Outcomes

By the end of the term, learners should be able to:

  1. Explain key concepts, roles, and functions of warehouse operations.
  2. Apply proper receiving, storage, and issuing procedures.
  3. Maintain accurate warehouse records and documentation.
  4. Implement appropriate inventory control methods.
  5. Apply health, safety, and security measures within warehouse operations.
  6. Use warehouse technologies such as barcode systems and WMS.
  7. Evaluate warehouse performance and propose improvements.

 

4. Weekly Course Breakdown (13 Weeks)

Week 1: Introduction to Warehouse Management

  • Meaning and purpose of a warehouse
  • Role of warehouses in supply chain
  • Types of warehouses (public, private, bonded, distribution centers)
  • Warehouse organization structure

Week 2: Warehouse Functions

  • Core functions: receiving, storage, picking, packing, dispatch
  • Support functions: quality checks, inventory reporting, security

Week 3: Warehouse Layout & Design

  • Importance of warehouse layout
  • Layout elements: docks, racking, aisles, staging areas
  • Space optimization and material flow
  • Factors influencing design

Week 4: Receiving and Inspection Procedures

  • Steps in receiving goods
  • Inspection for quality and quantity
  • Documentation: GRN, delivery notes, supplier invoice
  • Handling discrepancies

Week 5: Storage Systems & Materials Handling Equipment

  • Types of storage systems: shelving, pallet racks, bulk storage
  • Material handling equipment: forklifts, pallet jacks, conveyors
  • Factors in selecting storage systems
  • Safety considerations

Week 6: Inventory Management in the Warehouse

  • Inventory types: raw materials, WIP, finished goods
  • Inventory control methods: FIFO, LIFO, FEFO
  • Stock levels: maximum, minimum, reorder level
  • Stock rotation principles

Week 7: Warehouse Documentation and Record Keeping

  • Bin cards, stock cards, stock ledger
  • Issue documents: SIV, MRO, SRN
  • Importance of accurate record keeping
  • Digital vs manual records

Week 8: Warehouse Technology

  • Warehouse Management Systems (WMS)
  • Barcoding, RFID, scanners
  • Real-time data capture
  • Automation in warehouses

Week 9: Picking, Packing, and Order Fulfilment

  • Picking strategies (batch, wave, zone)
  • Packing procedures
  • Order accuracy and customer service
  • Managing dispatch

Week 10: Warehouse Safety, Security & Risk Management

  • Safety requirements (OSHA compliance)
  • Handling hazardous materials
  • Warehouse security: CCTV, access control
  • Common warehouse risks and mitigations

Week 11: Quality Control and Stocktaking

  • Cycle counting
  • Stocktaking methods: periodic, continuous
  • Variance analysis
  • Loss control and shrinkage management

Week 12: Warehouse Performance Measurement

  • KPIs: order accuracy, picking rate, inventory accuracy, turnaround time
  • Cost control in warehouse operations
  • Continuous improvement (Lean principles)

Week 13: Revision & Final Preparation

  • Review of key concepts
  • Past papers and practice questions
  • Exam preparation

 

5. Assessment Structure

Continuous Assessment Tests (CATs)

Total: 100 Marks

CAT 1 (Week 6) – 30 Marks

May include:

  • Short answer questions
  • Definitions
  • Calculations (inventory levels)
  • Practical examples on receiving/storage

CAT 2 (Week 12) – 70 Marks

May include:

  • Structured questions
  • Case study on warehouse operations
  • Practical application on documentation, WMS, safety

 

6. Main Exam

  • Final Exam (End of Term): 100 Marks
  • Covers all 13 weeks
  • Sections:
    • Section A: Short answer questions
    • Section B: Structured questions
    • Section C: Case study