DESIGN AND IMPLEMENTATION OF AN AUTOMATED INVENTORY CONTROL SYSTEM FOR A MANUFACTURING ORGANISATION

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Author

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Department of Computer Science

DESIGN AND IMPLEMENTATION OF AN AUTOMATED INVENTORY CONTROL SYSTEM FOR A MANUFACTURING ORGANISATION

( A Case Study Of Nigerian Breweries Plc, Enugu)

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.
TABLE OF CONTENT
Title page 
Approval Page 
Certification Page 
Dedication 
Acknowledgement 
Abstract 
Table of Contents 
List of Figures 
List of Tables

CHAPTER ONE
10 INTRODUCTION 

11 Background of the Study 
12 Statement of the Problem 
13 Purpose of the Study
14 Significance of the Study 
15 Objectives of the Study 
16 Scope of the Study 
17 Limitations of the Study 
18 Definition of Basic Concepts

CHAPTER TWO 
20 LITERATURE REVIEW 

21 Comprehensive Overview 
211 Purpose 
22 Types of Inventory Control Systems 
221 Four types of inventory control systems 
2211 Manual Inventory Management System 
2212 Barcode Technology 
2213 Radio Frequency Identification (RFID) 
2214 Warehouse Management System 
23 How Inventory Control Systems Really Work 
24 What Industries Use Inventory Control Systems 
241 Application of Inventory Control Systems 
242 Importance of Inventory Control Systems 
25 Warehouse Management Systems 
251 Warehouse Management Rules Engine 
2511 Rules Workbench 
2512 Warehouse Management System Strategy 
252 Importance of Warehouse Management Systems 
253 Inventory Control Systems vs Warehouse Mgt Systems 
26 Automated Inventory Control System Software

CHAPTER THREE 
3 0 SYSTEM ANALYSIS AND DESIGN 

31 Methodology 
32 Data Collection 
33 Analysis of the Existing System 
34 Limitation of the Existing System 
35 System Design 
36 Data Base Design 
37 Organizational Structure 
38 System Flow Chat 
39 Top down Design Diagram

CHAPTER FOUR 
40 IMPLEMENTATION, TESTING AND PACKAGING 

41 Choice of Development Tools 
42 System Requirements
421 Software Requirements 
422 Hardware Requirements 
43 Implementation 
436 Implementation of the Login Form 
437 Implementation of the Main menu form 
438 Implementation of the Receive Supply Form 
439 Implementation of Sales Form 
44 Implementation of Supplier Record Form 
441 Implementation 
45 Testing 
451 Unit Test 
452 System Test 
46 Packaging (Integration)

CHAPTER FIVE 
50 SUMMARY, LIMITATIONS, RECOMMENDATIONS, BEME &CONCLUSION 

51 Summary 
52 Limitation 
53 Recommendation 
54 Bill of Engineering Measurement & Evaluation (BEME) 
55 Conclusion 
References 
Appendix 1 
Source Code 
Appendix 1 Supply Form 
Appendix 2 Sales Invoice 
Appendix 3 Supplier Record 
Appendix 4 Customer Record

CHAPTER ONE

10 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

11 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

12 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

13 PURPOSE OF THE STUDY
The purpose of this study is to improve current operational process in the Nigerian Breweries PLC to its full capacity by developing efficient computer software that can handle inventory in a computerised fashion

14 SIGNIFICANCE OF THE STUDY 
This study is primarily aimed at increasing efficiency in operations, reducing maintenance and running cost, monitoring the supply of goods and its distribution and increase profit in the Nigerian Breweries PLC by introducing an automated inventory control system

15 OBJECTIVES OF THE STUDY 
The main objective of this study is to develop a computerised inventory control management system Others include;
i It provides total asset visibility
ii It allows reduced inventory stocking levels giving full inventory history
iii It reduces lead time, shelf space, and errors due to damage, fatigue of staff and overall cost of operations
iv It facilitates “just in time” deliveries
v It provides full process control for products
vi It provides higher level security as the system would be passworded to prevent unauthorised access
vii It shortens cross docking time and speeds up sort/pick up rate
viii It helps the management plan, monitor, optimize resources and ascertain their financial position at any time

16 SCOPE OF THE STUDY 
The scope of this study covers the Nigerian Breweries PLC as a whole, and its customers which include retailers, distributors and the general public

17 LIMITATIONS OF THE STUDY 
This project was constrained by the following factors: (a) Financial Constraints Bearing in mind the economic state of the nation, it was found difficult in making both ends meet, because of the exorbitant nature of things nowadays in travelling for the collection of data needed for the project (b) Time Constraints Looking at the interval between the resumption and vacation of the final semester for the project to be completed, the time given seemed to be short for the collection of required information for better work to be done (c) Non-Availability of Material During this project, it was noticed that the required materials needed for the project are not documented Those that were documented lacked storage facilities where they can be reached

18 DEFINITION OF BASIC CONCEPTS 
Automation: This is the use of technology or computers to control and process data reducing the need for human intervention
Database: This refers to a large store of related data on a computer that a user can access and modify Password: This is a secret code that must be entered into a computer to enable access to its applications It is made up of numbers, letters, special characters or a combination of any of the above categories Inventory Control System: A list of orders to be filled, and prompts workers to pick the necessary items and provides them with packaging and shipping information Computerization: This is the conversion of a manually operated system to a controlled, organized and automated system Research: A careful study of a subject to discover facts, establish a theory or develop a plan of action based on the facts discovered System: A set of computer components functioning together
Technology: The study of techniques of mobilizing resources such as information for accomplishing objectives that benefit man and his environment
Software: A computer program or set of instructions that direct a computer to perform processing functions Information System: A collection of procedures, people, instructions and equipment to produce information in a useful form Processing: This is dealing with something according to an established procedure

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