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LG - THHGAD0153A CONTROL AND ORDER STOCK

LEARNER’S GUIDE
CONTROL AND ORDER STOCK

Published by

HEART TRUST/NATIONAL TRAINING AGENCY

Produced by

TVET Resource Centre


Gordon Town Road
Kingston 7
Jamaica W.I.

*** 2003***

Version 1 CUR UNIT – JAN. 03


LG - THHGAD0153A CONTROL AND ORDER STOCK

LEARNER’S GUIDE

 2003 HEART Trust/NTA


Kingston
Jamaica

This material is protected by copyright. Copying this material or any part of it by any means,
including digital or in any form is prohibited unless prior written permission is obtained from
the HEART Trust/NTA.

Design and Development work


done by the Learning Resource
Unit of the TVET Resource
Centre

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LG - THHGAD0153A CONTROL AND ORDER STOCK

TABLE OF CONTENTS

PAGE

Introduction.......................................................................................................................... 1

Welcome ................................................................................................................... 1
This Competency Unit.................................................................................................... 1
Before You Start ............................................................................................................. 2
Planning Your Learning Programme ............................................................................. 2
Self-Assessment Checklist ............................................................................................. 2
How To Use This Learner’s Guide ................................................................................ 4
Using the Computer and Other Resources..................................................................... 6
Method of Assessment.................................................................................................... 6

Element 1: Maintain stock levels and records................................................................... 7

Self-Assessment Checklist ........................................................................................... 11

Element 2: Organise and administer stocktaking............................................................. 12

Self-Assessment Checklist ........................................................................................... 14

Element 3: Identify stock losses ........................................................................................... 15

Self-Assessment Checklist ........................................................................................... 17

Element 4: Process stock orders .......................................................................................... 18

Self-Assessment Checklist ........................................................................................... 20

Element 5: Follow up orders ................................................................................................ 21

Self-Assessment Checklist ........................................................................................... 22

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LG - THHGAD0153A CONTROL AND ORDER STOCK

LG-THHGAD0153A:
CONTROL AND ORDER STOCK

INTRODUCTION

Welcome

Welcome to the Learner’s Guide for Unit of Competency “Control and Order Stock”.
This is just one of a number of Learner Guides produced for the Commercial Food
Preparation Skills stream of the Tourism and Hospitality Industry, and it is designed to
guide you, the learner, through a series of learning processes and activities that will
enable you to achieve the specified learning outcomes for the competency unit.

The content of this guide was developed from the Competency Standard
THHGAD0153A which is one of the basic building blocks for the National Vocational
Qualification of Jamaica (NVQJ) certification within the industry. Please refer to your
Learner’s Handbook for a thorough explanation of standards and competencies, and how
these relate to the NVQJ certification.

This Competency Unit

“Control and order stock” addresses the knowledge and skills requirements for
effectively selecting, preparing, controlling and ordering stock. Five elements are
presented:

Element 1: Maintain stock levels and records

Element 2: Organise and administer stocktaking

Element 3: Identify stock losses

Element 4: Process stock orders

Element 5: Follow up orders

You are also advised to consult the Competency Standard for a better understanding of
what is required to master the competency.

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Before you start

Before you start this Learner’s Guide you need to:

a. Obtain a Learner Logbook that will be used to record evidence of your new
skills/competence. As you demonstrate your new skills, record your activities and
have your learning facilitator sign off on them. This will allow you to provide
evidence of your competence when you are being assessed against the competency
standard.

b. Ensure that you have access to the facilities and equipment necessary for learning.

c. Ensure that your learning resources are available.

d. Know and observe the occupational health and safety standards/practices for the
industry. For example, ensure that you are wearing suitable clothing, that tools and
equipment are safe, and that the correct safety equipment is used.

e. Plan you learning programme (see below)

f. Understand how to use this Learner’s Guide (see below)

Planning you learning programme

The following self-assessment checklists will assist you in planning your learning
programme as they will help you to think about the knowledge and skills needed to
demonstrate competency in this unit. As you go through each one you will be able to
find out what competencies you already have and what competencies you will need to
pay more attention to as you go through the learning process.

To complete the checklists simply read the statements and tick the ‘Yes’ or ‘No’ box.

Self-Assessment Checklist
- Control and order stock

Element 1 Maintain stock levels and records Yes No

1. I can monitor and maintain stock level as prescribed


by enterprise ___ ___

2. I can monitor and adjust stock security systems as required ___ ___

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3. I can monitor and adjust stock re-order cycles as required ___ ___

4. I can maintain stock storage and records in


accordance with enterprise procedures ___ ___

5. I can maintain stock performance and identify fast/slow


selling items in accordance with enterprise procedures ___ ___

Element 2 Organise and administer stocktaking Yes No

1. I can organise stocktaking at the appropriate


times and allocate responsibilities to staff ___ ___

2. I can identify typical stocktaking procedures as


appropriate to industry sector ___ ___

3. I can prepare accurate reports on stocktaking ___ ___

Element 3 Identify stock losses Yes No

1. I can identify avoidable losses and establish reasons


for loss ___ ___

2. I can follow the procedure to report losses ___ ___

3. I can recommend and implement solutions to prevent


future available losses ___ ___

Element 4 Process stock orders Yes No

1. I can process order for stock accurately and in


accordance with enterprise procedure ___ ___

2. I can maintain stock ordering and recording systems


accurately ___ ___

3. I can use purchase and supply agreements and


record the appropriate detail ___ ___

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Element 5 Follow up orders Yes No

1. I can monitor the delivery process to meet agreed


deadlines ___ ___

2. I can liaise with colleagues and supplier to ensure


continuity of supply ___ ___

3. I can distribute stock in accordance with agreed


allocations ___ ___

If you ticked all or most of the ‘Yes’ boxes, then you might not need to go through the
entire guide. Ask your learning facilitator to assist you in determining the most
appropriate direction for this competency.

If you ticked few of the ‘Yes’ boxes or none at all, then you should work through the
entire guide, even though some of the materials may be familiar to you.

Plan your learning based on your answers. Be sure to involve your learning facilitator in
the planning process.

How to use this Learner’s Guide

This Learner’s Guide is designed to assist you work and learn at your own pace.

We suggest that you:

• Go through the sections/elements as they are presented (starting at Section 1)

• Check your progress at each checkpoint to ensure that you have understood the
material

• Observe the icons and special graphics used throughout this guide to remind you of
what you have to do and to enhance your learning. The icons and their meanings are
as follows:

Complete Assessment Exercise


Requires you to think about the knowledge and skills that
you have or will develop in this competency unit.

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Definition Box
Words/phases are defined or explained in this box. The
words/phases being explained are in bold print.

Checkpoint

This denotes a brain teaser used to check your


understanding of the materials presented. No answers are
provided for the questions asked.

Activity
This denotes something for you to do either alone or with
the assistance of your learning facilitator.

Reference
Points you to the reference materials and other support
documents or resources used in compiling the unit content.

• Ask your learning facilitator for help if you have any problem with the interpretation
of the contents, the procedures, or the availability of resources

• Stop and complete each activity as you come to it. If the activity requires you to
perform an actual task, be sure to tell your learning facilitator when you get to that
activity so he/she can make any arrangements

• Get your learning facilitator to sign and date the Learner Logbook when you have
completed an activity

• Read the summary and complete the self-assessment checklist at the end of each
section or element.

When you have worked through all sections of the guide, complete the assessment
exercise at the end of the document. When you can tick every ‘Yes’ box, you are ready
for assessment and may ask your learning facilitator to assist you in making the
arrangement to have your performance assessed.

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Using the Computer and Other Resources

Where your activities refer you to the library, computer and Internet resources, ask your
learning facilitator to assist you with locating these resources. If you are getting your
training in an institution, there may be a library and computer laboratory. If this is not
the case, visit the local library and find out what resources are available.

If you are new to the computer and the Internet, someone should be able to show you
how to use these resources.

Please note that in many of your activities you have been referred to information on the
Internet. This is because the Internet has a vast amount of information that can help you
in acquiring the particular competencies. We would like to advice you, however, that we
cannot guarantee that all the sites will be available when you need them. If this happens,
ask your learning facilitator to assist you with locating other sites that have the
information you require.

Method of Assessment

Competency will be assessed while work is undertaken under direct supervision with
regular checks, but may include some autonomy when working as a team. You are
advised to consult the associated competency standard for further details related to the
assessment strategies.

You may now start your learning. Have fun while you work!

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ELEMENT 1: MAINTAIN STOCK LEVELS AND RECORDS

LEARNING OUTCOMES

As you go through this element you acquire the necessary knowledge, skills and attitude
needed to maintain stock levels and records. Your learning facilitator is there to assist
you with different activities. On completion you should be able to:

1. Monitor and maintain stock levels as prescribed by enterprise


2. Monitor and adjust stock security systems as required
3. Maintain, monitor and adjust stock reorder cycles as required
4. Inform colleagues of their individual responsibilities in regard to recording
stock
5. Maintain stock storage and movement of records in accordance with
enterprise procedures
6. Monitor stock performance and identify and report fast/slow selling items in
accordance with enterprise procedures

MONITOR AND MAINTAIN STOCK LEVELS

Re-order point - the


inventory/stock position
when a new order should be
placed.

Each company has to determine the level of stock it wants to carry. Once determined,
systems must be put in place to monitor and maintain them.

• Stock movement may be tracked manually and an order placed when the reorder
point is reached, as indicated by entries on the stock card. Manual tracking
requires that the stock clerk be alert and make daily checks on his stock.
• They are many software applications available to monitor stock electronically.
Once various critical points are determined and entered, these systems
automatically alert you to changes that need your attention. Your computer will
tell you (a) which item needs to be re-ordered now (b) what product’s shelf life
has expired (c) the products that are too long in the inventory (d) prints ,purchase
requisition and orders will give you reminder regarding time frame

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CHECKPOINT:
Why is it important to monitor stock levels?
What is the likely result of stock levels falling below the lower limit?

STOCK SECURITY SYSTEMS

Bar code - UPC/ Universal


Product Code identifies storage
information on a product/item.

• Unique number or bar code assigned to stock item/product for identification.


• Records are kept of receipt and/ or deliveries of any item into or out of stock
• Product is removed from stock only on receipt of properly completed goods
requisition form
• Unauthorised persons are not allowed into stock room
• Stock is stored or moved in accordance with FIFO (first-in first-out)

Monitor and adjust stock re-order cycles

Although stock levels are pre-determined, and the order quantity and cycles determined
by applying the EOQ inventory model and might make it necessary to adjust to order
quantity and re-order cycles based on:

• Movement of stock item owing to faster or slower usage


• Spoilage
• Breakage
• Menu changes
• Seasons

Stable or improved inventory costs are a result of continuous monitoring and appropriate
and timely adjustments.

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Colleagues- responsibilities and stock records

For any system to function efficiently all parties involved must be aware of and respect
the terms and conditions of service. Whenever stock is purchased, received, requested
from storage, delivered, dumped or disposed of, no matter the manner, the appropriate
forms/cards or data entry must be made or completed.

Maintain stock storage and movement records

Record keeping is an important aspect of stock control. It provides for the accounting
department, the inventory cost and pricing information they usually require. It also
eliminates the need to count stock each time stock is added or removed. Entering stock
movement as soon as it occurs ensures a perpetual record is available. Periodic stock
counts confirm stock record balances and identify overages or shortages.

CHECKPOINT:
Give reasons record keeping is necessary for proper stock control?

Monitor Stock Performance

Stock performance should be monitored consistently. As management tools, records


should be kept current. Fast/slow selling stock should be reported to the relevant
authority/purchasing officer, adjustments to the order frequency or order quantity. The
production department should also be informed as the stock level in production changes.

CHECKPOINT:
What do FIFO and EOQ mean? How are they used in stock control?

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ACTIVITY:

Ask your learning facilitator to help you review records being used in
your institution to control and order stock. You should be provided
with practical examples. Complete copies of different requisition
forms/letters used and write a report on how stock records facilitate
control and traceability of stock within your organisation.

Pay attention to the stock item description

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READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the
components by doing the following Self-Assessment.

Checklist 1
Yes No

1. I understand how to monitor and maintain stock levels


as prescribed by enterprise ___ ___

2. I understand how to monitor and adjust stock security


systems as required ___ ___

3. I understand how to monitor and adjust stock re-order


cycles as required ___ ___

4. I understand how to maintain stock storage and


movement records according to enterprise procedures ___ ___

5. I understand how to maintain stock performance and


identify fast/slow-selling items in accordance with
enterprise procedures ___ ___

Checklist 2
Yes No

1. Stock levels are maintained and monitored as


prescribed by enterprise ___ ___

2. Stock security systems are monitored and


adjusted as required ___ ___

3. Stock storage and movement records are maintained


according to enterprise procedures ___ ___

4. Fast/slow selling items and stock performance are


maintained and identified ___ ___

5. Colleagues are informed of individual


responsibilities in regarding to recording of stock ___ ___

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ELEMENT 2: ORGANISE AND ADMINISTER STOCKTAKES

LEARNING OUTCOMES

As you go through this element you need to ensure that you acquire the necessary
knowledge, skills and attitude needed to organise and administer stocktaking. Your
learning facilitator is there to assist you with the different activities. On completion you
should be able to:

1. Organise stocktakes at the appropriate time and allocate responsibilities to


staff
2. Produce within the designated timelines accurate reports on stocktake data
3. Identify standard stocktaking procedures

ORGANISE STOCKTAKES

Stocktaking: the listing


and counting of items in
stock

Periodic stocktaking is usually requested by the accounting department.. The data


obtained from the exercise is used in the preparation of the company’s financial
statements and for costing of the stock items or products in which stock items are used.
Organising a stocktake:

• Identify stock to be counted


• Confirm location of stock
• Assemble stocktaking team
• Instruct team on method to be used for exercise
• Prepare tools (paper, pencils, pens, inventory list, gear, etc.
• Advise auditors, if stipulated
• Confirm date, time and place for stocktaking

The stock control personnel may do stocktaking on an ad hoc basis to verify particular
item(s).

CHECKPOINT
List some stocks that may be included when doing stocktaking. How
you would organise stocktaking in a linen room

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Stocktaking Reports

As soon as stocktaking is completed, data must be collated, re-checked and compared


and a report submitted in the form required by the enterprise/company.

Stocktaking Procedure

A stock list is prepared with the items usually stocked.


• The stock is located
• The identifying marks are compared with that on the list
• The stock is counted /weighed and recorded
• Have team members verify count or weight. Team members usually work in
pairs.
• The stocktake data is collated
• A report is prepared and presented to relevant body.
• Make adjustments (overages or losses) to stock record once authorisation is
obtained from the relevant body, e.g. accounts.

Pay attention to detail when organising stocktaking

CHECKPOINT
Give reasons a company practices periodic stocktaking?

ACTIVITY
Discuss with your learning facilitator the organising and holding of a
stocktaking exercise by the class. You may suggest organising the
stock in a dry ingredients storage area or in a cold room stock.
Outline your plan of action and identify what is required of each
participant. Estimate how much time you would need to carry out
this exercise. Submit a report of the stocktaking to your learning
facilitator.

Reference; LG THHGAD0141A Receive and store stock


Anderson, David R., Sweeney, Dennis T. & Williams, Thomas A.
(1994), Quantitative Approaches to Decision Making 7th Ed. Chapter 2

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ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, do the following Self-Assessment to see
whether you grasped fully its component.

Checklist 1
Yes No

1. I understand how to organise stocktaking at


appropriate times and allocate responsibilities to staff ___ ___

2. I understand how to identify standard stocktaking


procedures ___ ___

3. I understand how to prepare accurate stocktaking


reports ___ ___

Checklist 2
Yes No

1. Stocks are organised at appropriate times and responsibilities


allocated to staff ___ ___

2. Stocktaking procedures are identified as meeting


industry standards ___ ___

3. Attention is paid to detail when organising and


administering stocktaking ___ ___

4. Accurate reports on stocktaking data are produced within


designated deadlines ___ ___

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ELEMENT 3: IDENTIFY STOCK LOSSES

LEARNING OUTCOMES

As you go through this element you need to ensure that you acquire the necessary
knowledge, skills and attitude needed to identify stock losses. Your learning facilitator is
there to assist you with the different activities. On completion you should be able to:

1. Identify losses accurately, record and assess against potential loss


forecasts on a regular basis.
2. Report losses in accordance with enterprise/company procedure
3. Identify avoidable losses and establish reasons for loss
4. Recommend and implement solutions to prevent avoidable losses in the future

IDENTIFY LOSSES

Whether periodic or ad hoc, on completion of a stocktaking exercise, stock losses may be


identified. Stock losses are differences between quantity/weight on record and the
physical count. Stock losses may be attributed to careless record keeping, breakages/
spillages, pilfering, damage or infestation by pests and incorrect storage. These losses
should be assessed and compared with the forecast for potential losses on a regular basis.
Such assessment and comparison will inform the financial effect on the operations.

Reporting Stock Losses

Losses should be reported to the relevant body as soon as they are identified. The report
should be submitted according to the procedure stipulated by the enterprise. Where
possible, the report should include an explanation for the loss and its cost.

CHECKPOINT:
Can you identify potential stock losses?
Are they avoidable?

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Avoidable losses

Some stock losses may be prevented by exercising due care:

• Breakages
• Infestation
• Improper storage
• Inaccurate record keeping
• Pilferage

Investigating why avoidable losses occur should be undertaken to prevent their


recurrence.

Solutions

Avoidable losses may be prevented by:

• Staff training
• Developing and implementing pest control programme
• Storing products/stock in the recommended environment
• Securing the storeroom and allowing only authorised personnel to enter or remove
stock
• Re-visiting the lay out of the storeroom and assessing accessibility of stock

CHECKPOINT:
Can you calculate the cost of stock losses identified during recent
stocktaking?

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ACTIVITY:

List the number of avoidable stock losses observed in your institution


and submit a report outlining how you would reduce or eliminate
such losses. Indicate what savings would be realised if your
solutions are implemented. Ask your learning facilitator to assist you
with obtaining stock item prices/costs.

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, do the following Self-Assessment to see
whether you have grasped fully all its components.

Checklist 1
Yes No
1. I understand how to identify avoidable losses and
establish reasons for loss ___ ___

2. I understand how losses are reported ___ ___

3. I understand how to recommend and implement


solutions to prevent avoidable losses in the future ___ ___

Checklist 2
Yes No

1. Losses are reported in accordance with


enterprise/company procedures ___ ___

2. Solutions are recommended and implemented to


prevent avoidable losses in the future ___ ___

3. Avoidable losses are identified, their reasons


established and a report made in accordance with
company procedures ___ ___

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ELEMENT 4 PROCESS STOCK ORDERS

LEARNING OUTCOMES

As you go through this element you need to ensure that you acquire the necessary
knowledge, skills and attitude needed to process stock orders. Your learning facilitator is
there to assist you with different activities. On completion you should be able to:

1. Process orders for stock accurately and in accordance with enterprise


procedures
2. Maintain stock ordering and recording systems accurately
3. Correctly use purchase and supply agreements and record appropriate details

PROCESS ORDERS FOR STOCK

• Prepare purchase requisition. Requisition should: display item; identify a supplier;


state quantity needed; state cost of item and expected delivery date.
• Obtain purchase order from designated authority within the enterprise.
• Check the purchase order to see it accurately reflects the purchase requisition
• Send purchase order to supplier
• Check delivery status with supplier

Purchase order: A letter or prescribed


form authorising purchase of an item
from a supplier.

Be accurate when processing records

Maintain Stock Ordering and Recording Systems

• A file/copy of the purchase order should be kept


• As soon as an order is received update the stock control system
• Update system with changes in specifications, stock number and supplier as soon
as notification is received
• Review high limits and low limits and re-order points
• All stock movements must be recorded.
• Do random spot checks to verify records

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Purchase and Supply Agreements

Purchase and supply agreements outline specific terms and conditions of purchases and
supplies between individuals or enterprises. They may relate to:

• Quantity discounts
• Product guarantees
• Payments
• Method of shipping/transportation
• Pricing
• Minimum order quantity
• Quality
• Product usage
Details of these agreements must be adhered to when ordering or supplying goods.

CHECKPOINT
What are purchase and supply agreements?
How would you process an order for 10 cases of dinner plates?

ACTIVITY

Draft a purchasing agreement for purchasing kitchen equipment. Ask


your learning facilitator to assist/guide you.
Make a study of your institution’s stock ordering and recording
system. Is it an efficient and effective system?
Have your learning facilitator arrange for you to observe at least two
other systems operating elsewhere so you will be able to make
comparisons.

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Reference: LG THHGAD0141A Receive and Store Stock


LG THHCFP0342A Identify and Prepare Meat
COMMIS CHEF L2 2001 HEART Trust NTA M1 unit 2 p19-21

Ask your learning facilitator how to access?

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, do the following Self-Assessment to see
whether you have grasped fully its components.

Checklist 1
Yes No

1. I understand how to process stock orders accurately and


in accordance with enterprise procedure ___ ___

2. I understand how to maintain stock ordering and recording


systems accurately ___ ___

3. I understand how to use purchase and supply agreements


and how to record the appropriate detail ___ ___

Checklist 2
Yes No

1. Orders for stock are accurately processed in accordance


with enterprise/company procedures ___ ___

2. Stock orders and record system are accurately maintained ___ ___

3. Purchase and supply agreements are appropriately used


to record detail ___ ___

4. Accuracy is displayed when processing stock order ___ ___

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ELEMENT 5 FOLLOW UP ORDERS

LEARNING OUTCOMES

As you go through this element you acquire the necessary knowledge, skills and attitude to follow
up orders. Your learning facilitator is there to assist you with the different activities. On completion
you should be able to:

1. Monitor delivery process to meet agreed deadlines


2. Liaise with colleagues and supplier to ensure continuity of supply
3. Distribute stock in accordance with agreed allocations.

MONITOR DELIVERY PROCESS

Once the supplier receives the order, and a delivery date is agreed on, the stock controller contacts
the supplier at regular intervals to ascertain the status of the order and whether the delivery deadline
will be met. Preparations are made to receive and store the goods when delivered.

Liaise with Colleagues and Supplier communicating by fax

• Purchase requisition and purchase order are prepared in good time and dispatched to the
supplier as soon as possible.
• Consult with colleagues about the urgency of the order and confirm optimum delivery date.
• Liaise with supplier and ensure the goods will be available at the specified time
• Supply agreements are checked
• Confirm delivery date for any back order

Distribute Stock

• Goods requisition order is received by the stock clerk


• Goods are located and assembled according to requisition
• Goods are delivered to department or person who requested the goods
• The stock card is updated to reflect the delivery.

Be careful when delivering stocks

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CHECKPOINT
What steps would you take to ensure your order is delivered within
agreed deadlines?

ACTIVITY

Have your learning facilitator arrange time for you in the receiver
and delivery department of your company. Write a report detailing
the delivery, receival and storage procedures. Discuss your
findings/observations with your learning facilitator.

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, do the following Self-Assessment to see whether you
have grasped fully all it components.

Checklist 1
Yes No
1. I understand how to monitor the delivery process to meet
agreed deadlines ___ ___

2. I understand how to liaise with colleagues and supplier to


ensure continuity of supply ___ ___

3. I understand how to distribute stock in accordance with


agreed allocations ___ ___

Checklist 2
Yes No

1. Delivery process is monitored to meet agreed deadlines ___ ___

2. Colleagues and supplier have ensured continuity


of supply ___ ___

3. Stock is distributed in accordance with agreed


allocations ___ ___

4. Carefulness is displayed when delivering stock ___ ___

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