Design And Implementation Of An Automated Inventory Control System For A Manufacturing Organisation

ABSTRACT
This research work is concise and generally summarizes the activities duly carried out in the design and implementation of an automated inventory control system for a manufacturing organization. The system is designed to efficiently handle the movement and tracking of goods through the replacement of human workers by technology. The manual method or intervention is labour intensive, costly, and error prone and cannot ensure the inventory remains up-to-date due to oversight and internal shrinkage. With the proposed new system, inventory can be updated in real time without product movement, scanning, or human involvement. The automated system allows inventory status to be determined and shipping and receiving documents to be generated automatically triggering automatic orders for products that are low in inventory. The study outlines the main concepts of the analysis and design methodology of the proposed system, compares it to the existing and goes further to explain the design and implementation of the system using Visual Basic 6.0 for the database. The fact finding techniques employed is interview, observation, online and library research.
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TABLE OF CONTENTS Title page i Approval Page ii Certification Page iii Dedication iv Acknowledgement v Abstract vii Table of Contents viii List of Figures xiv List of Tables xv CHAPTER ONE
1.0 Introduction - - - - - - - 1
1.1 Background of the Study - - - - - 2 1.2 Statement of the Problem - - - - - 3 1.3 Purpose of the Study - - - - - - 4
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1.4 Significance of the Study - - - - - 4 1.5 Objectives of the Study - - - - - - 4 1.6 Scope of the Study - - - - - - 5 1.7 Limitations of the Study - - - - - - 6 1.8 Definition of Basic Concepts - - - - - 6 CHAPTER TWO 2.0 Literature Review - - - - - - 9 2.1 Comprehensive Overview - - - - - 9 2.1.1 Purpose - - - - - - - - 10 2.2 Types of Inventory Control Systems - - - - 10 2.2.1 Four types of inventory control systems - - - - 11 2.2.1.1 Manual Inventory Management System - - - 11 2.2.1.2 Barcode Technology - - - - - - 12
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2.2.1.3 Radio Frequency Identification (RFID) - - - 13 2.2.1.4 Warehouse Management System - - - - 14 2.3 How Inventory Control Systems Really Work - - 16 2.4 What Industries Use Inventory Control Systems - - 19 2.4.1 Application of Inventory Control Systems - - - 20 2.4.2 Importance of Inventory Control Systems - - - - 21 2.5 Warehouse Management Systems - - - - 22 2.5.1 Warehouse Management Rules Engine - - - 24 2.5.1.1 Rules Workbench - - - - - - 25 2.5.1.2 Warehouse Management System Strategy - - - 25 2.5.2 Importance of Warehouse Management Systems - - 25 2.5.3 Inventory Control Systems vs. Warehouse Mgt Systems - 27 2.6 Automated Inventory Control System Software - - - 28
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CHAPTER THREE 3.0 System Analysis and Design - - - - - 30 3.1 Methodology - - - - - - - 30 3.2 Data Collection - - - - - - - 30 3.3 Analysis of the Existing System - - - - - 31 3.4 Limitation of the Existing System - - - - 32 3.5 System Design - - - - - - - 33 3.6 Data Base Design - - - - - - - 35 3.7 Organizational Structure - - - - - - 38 3.8 System Flow Chat - - - - - - - 42 3.9 Top down Design Diagram - - - - - 44 CHAPTER FOUR 4.0 Implementation, Testing and Packaging - - - 46
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4.1 Choice of Development Tools - - - - - 46 4.2 System Requirements - - - - - - 46 4.2.1 Software Requirements - - - - - 46 4.2.2 Hardware Requirements - - - - - 47 4.3 Implementation - - - - - - - 48 4.3.6 Implementation of the Login Form - - - 53 4.3.7 Implementation of the Main menu form - 54 4.3.8 Implementation of the Receive Supply Form - 55 4.3.9 Implementation of Sales Form - - - - 55 4.4 Implementation of Supplier Record Form- - - - 57 4.4.1 Implementation - - - - - - 58 4.5 Testing - - - - - - - - 58 4.5.1 Unit Test - - - - - - - - 60 4.5.2 System Test - - - - - - - - 60
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4.6 Packaging (Integration) - - - - - - 60 CHAPTER FIVE 5.0 Summary, Limitations, Recommendations, Beme &Conclusion 61 5.1 Summary - - - - - - - - 61 5.2 Limitation - - - - - - - - 63 5.3 Recommendation - - - - - - - 63 5.4 Bill of Engineering Measurement & Evaluation (BEME) - 65 5.5 Conclusion - - - - - - - - 66 References - - - - - - - - 67 Appendix 1 - - - - - - - - 70 Source Code - - - - - - - 70 Appendix 1 Supply Form - - - - - - 78 Appendix 2 Sales Invoice - - - - - 79
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Appendix 3 Supplier Record - - - - - - 80 Appendix 4 Customer Record - - - - - - 81
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List of figures Fig 3.7 Organizational Structure - - - - - - - -41 Fig 3.8 System Flowchart - - - - - - - -43 Fig 3.9 Top down Design Diagram - - - - - - - -44 Fig 4.3.1 Implementation of Program Design Process - -49 Fig 4.3.2 Data Base Entry and Search Engine - - - - - 50 Fig 4.3.3 Main Menu Transaction Process (Receive supply) 51 Fig 4.3.4 Main Menu Transaction Process (Sales form) - 52 Fig 4.3.5 Main Menu Transaction & Exit (sales form) - -53 Fig 4.3.6 Splash Screen; the Login Screen - - -53 Fig 4.3.7 Main menu form - - - - - - -54 Fig 4.3.8 Receive supply form - - - - - -55 Fig 4.3.9 Sales form - - - - - - - -56
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Fig 4.4 Supplier record form - - - - - - 57 Fig 4.4.1 Edit form - - - - - - - - 58 Fig 4.5 System Testing Process - - - - - - 59
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LIST OF TABLES 3.6 Data base; login table - - - - - - - - - - - 35 3.6.1 Transaction table; supply form - - - - - - 36 3.6.2 Sales Table - - - - - - - - - 37 3.6.3 Customers Table - - - - - - - - 38 5.1 Bill Of Engineering Measurement & - - - - - 65
Evaluation (BEME)
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CHAPTER ONE 1.0 INTRODUCTION An inventory control system contains a list of orders to be filled and then prompts workers to pick the necessary items, and provides them with packaging and shipping information. Inventory control may be used to automate sales order fulfilment process and also manage in and outward material of hardware. Automation is the replacement of human workers by technology. For optimal sales and inventory management process, robust functionality is needed for managing logistics facilities. Warehouse management functions for inventory control cover internal warehouse movements and storage and its support helps in the recording and tracking of materials on basis of both quantity and value.
This application takes care of all supply orders reducing cost for warehousing, transportation while improving customer service. It significantly improves inventory turns, optimizes flow of goods. It also improves cash flow, visibility and decision making providing efficient execution of tasks using this fast and reliable computerised method
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1.1 BACKGROUND OF THE STUDY The Nigerian Breweries PLC was established in the year 1946. It aims at providing satisfaction and nourishment to the Nigerian population through the distribution of drinks like beer, coca-cola, fanta, sprite etc. It is second to none and for this reason, the demand is high and the company responds to the increasing demand by stabilizing supply to strike a balance. Justifiably, the company has the problem of keeping adequate record of goods transfer and since it is done manually, associated problems of insecurity, high cost of operation and delay in supply arise. Data processing in Nigerian Breweries PLC is presently carried out using people, pens, and paper to control stock and inventory. The design and development of an automated inventory control system for the Nigerian Breweries PLC will no doubt bring immeasurable relief from the problems associated with the manual system.
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1.2 STATEMENT OF THE PROBLEM The Nigerian Breweries PLC is to an extent manually operated and reveals a number of problems.
 The recording of sales and cash received are done manually on a book that appears rough. Thus, the books are exposed to physical damage, information can be lost and dust particles are accumulated.
 The long list of supply orders waiting to be attended to on daily basis.
 The control system is time consuming, less accurate and less efficient, and the environment is not user friendly.
 Inaccuracies often ensue from human error.
The manual system is quite tedious and can be reduced or eliminated with the introduction of the proposed system.