1. Production & Warehouse Manager or concerned department heads will request for opening a new code. The request is verbal through telephonic conversation Or in the meeting, E-mail. Please Note: The code could be Raw Material or Production Material as Mr. Samer is in charge of both production and warehouse.
📌 Item Master - Block
🗂️ Source: PKF
🔧 Steps:
1. Periodic Item Review: Biannual (Twice a year), the Warehouse Manager prepares a report showing the status of all item codes and identifies inactive codes (those with no quantity and/or value).
📌 Purchase Request - Production & Consumables
🗂️ Source: PKF
🔧 Steps:
Request Initiation: Store Keeper receives material request and creates a PR in the ERP system with full item details.
📌 Vendor Quotation – Production & Consumables
🗂️ Source: PKF
🔧 Steps:
Vendor Check: Procurement verifies if approved vendors exist. If not, sources new vendors.
📌 Purchase Order – Production & Consumables
🗂️ Source: PKF
🔧 Steps:
1. Initiate PO: The Stores Supervisor prepares the Purchase Order in coordination with the approved Material Request and quotation.🔹 Note: PO price must be confirmed by the Procurement Manager before proceeding.
📌 Good Receipt Note (GRN)
🗂️ Source: UHY
🔧 Steps:
1. When a shipment arrives at the gate, they will report to the gate keeper security. After initial checking, the security will inform the Stores Keeper
📌 Material Return
🗂️ Source: UHY
🔧 Steps:
1. Responsibility for Supplier Communication in Case of Returns
📌 Stores Quality Management
🗂️ Source: UHY
🔧 Steps:
1. On a daily basis, the Storekeeper will visit each store in the premises and document the following:
📌 Material Movement - Concentrate
🗂️ Source: UHY
🔧 Steps:
1. Once the material is depleted in the Production Store, Concentrate will be moved from Main Store to the Production Store as per space availability and upcoming production requirements. The movement of contrate item is documented in 'Concentrate Handover Report'.
📌 Material Movement - Row Materials & Primary Materials(2 Slides)
🗂️ Source: UHY
🔧 Steps:
1. Weekly Production Schedule Preparation: The Production Team prepares the weekly production schedule and communicates it to the Stores and Warehouse teams for necessary material arrangements.
📌 Material Movement - Row Materials & Primary Materials(2 Slides)
6. Daily Stock Reporting and Control: The Stores Supervisor updates the 'Raw Material Stock Report' control sheet in MS Excel daily. This sheet is used to monitor:• Upcoming material deliveries and ordering schedules• Forecast accuracy• Daily concentrate aging report🔎 Note: Although this information exists in the ERP system, MS Excel is still used for customized tracking and personal control.📧 These reports are emailed daily to the Stores and Warehouse Manager.💻 System: Partially✅ Implemented: Yes 👥 Approver: Stores Supervisor, Warehouse Manager, Production Supervisor, Production Manager 🧭 Involved: Stores Keeper, Stores Supervisor, Warehouse Manager, Production Supervisor, Production Manager ⚠️ Notes: Need to change the workflow process
📌 Monthly Wastage Analysis
🗂️ Source: UHY
🔧 Steps:
1. On a monthly basis, Stores Supervisor will update 'Monthly Wastage Report' control sheet in MS Excel to identify the yield % and wastage analysis. Note: This report is emailed to Stores & Warehouse Manager on a monthly basis.
📌 Physical Verification - Daily Raw Materials and Packing Material
🗂️ Source: UHY
🔧 Steps:
The Store Keeper is responsible for performing physical verification of all raw materials issued to production. This includes, but is not limited to, the following items:
📌 Physical Verification - Monthly Raw Materials and Packing Material
🗂️ Source: UHY
🔧 Steps:
1. Month-End Stock Count by Stores Team: On the last day of each month, the Storekeeper, together with the Stores Supervisor, performs a physical stock count on the shop floor. The findings are updated in the printed ‘Raw Material Stock Report’, and any variances identified are reported to the Stores & Warehouse Manager for review.
📌 Physical Verification – External Raw Materials and Packing Material Stock Count
🗂️ Source: UHY
🔧 Steps:
1. During the last day of the year, the Store Team along with External Auditors will conduct yearly stock count and variances if any are investigated.
📌 Material Movement - Spare Parts_Plant
🗂️ Source: UHY
🔧 Steps:
When a spare part is required for plant equipment, the Maintenance In-Charge raises a ‘Material Request’ and submits it to the Stores.➤ Stock availability is verified in the system.
📌 Return of Used Spare part
🗂️ Source: UHY
🔧 Steps:
After completing the maintenance activity, the Maintenance In-Charge evaluates whether the replaced spare part is reusable or not.➤ A ‘Spare Return / Scrap Note’ is then issued and submitted to the Store.
📌 Material Movement_QC Consumables
🗂️ Source: UHY
🔧 Steps:
1. When QC Consumables are required, the QC In-Charge raises a ‘Material Request’ and submits it to the Stores.➤ Stock availability is checked in the system.
📌 Material Movement - Spare parts for Fleet and MEM
🗂️ Source: UHY
🔧 Steps:
When a spare part is required for Fleet or MEM equipment, the Maintenance In-Charge raises a ‘Material Request’ and submits it to the Stores.➤ Stock availability is verified in the system.
📌 Waste Management (Recyclable)
🗂️ Source: UHY
🔧 Steps:
The Stores Supervisor coordinates with the waste service provider to ensure the daily collection of recyclable waste from the premises.
📌 Waste Management (Hazardous)
🗂️ Source: UHY
🔧 Steps:
The Stores Supervisor coordinates with the approved waste collection service provider for the removal of recyclable waste, based on operational needs.
📌 Waste Management (General)
🗂️ Source: UHY
🔧 Steps:
The Stores Supervisor coordinates with the designated service provider to arrange for the collection of general waste, based on operational requests.
📌 TADWEER Reporting
🗂️ Source: UHY
🔧 Steps:
1. Store Department will prepare and submit Waste Reduction - Yearly Report to TADWEER
