As an Executive, you will build, execute, and continuously improve a perpetual (cycle) inventory counting program based on ABC classification to ensure >99% inventory accuracy, minimal stock variances, and audit-ready controls across plants and storage locations in SAP (S/4HANA/MM/EWM). The role drives risk-based counting frequencies, root-cause analysis of discrepancies, and cross-functional corrective actions with Stores, Production, Procurement, Planning, and Finance.
Key Responsibilities:
A. ABC Analysis & Policy Setup
- Define and maintain ABC classification rules (consumption value, criticality, lead time, shrinkage risk) and update cycle counting indicators in SAP material masters (e.g., MM02 → Plant data/Stor. 2 → Cycle counting indicator).
- Determine and publish count frequencies (e.g., A = monthly; B = quarterly; C = semi‑annual/annual) and align with Finance for control requirements.
- Maintain the perpetual counting calendar per plant/storage location/bin; coordinate with Operations to avoid production disruptions.
B. SAP Process Execution (MM/IM/WM/EWM)
- Create, schedule, and monitor physical/cycle count documents (e.g., MI01/MI31, MI04, MI07, MI20, MI21; and EWM cycle counting tasks).
- Ensure count sheet issuance, blind counts, and timely posting of differences with correct reason codes and approvals.
- Drive bin-level accuracy in WM/EWM (HU/bin corrections, RTS, stock type, quant updates).
- Manage block/unblock controls during counts to prevent movements and ensure data integrity.
- Reconcile MB5B/MB52 variances with FI-GL and movement type analysis (e.g., 101/261/309/311 corrections).
C. Controls, Compliance & Audit Readiness
- Implement SoD-compliant processes: separation between counters, posters, and approvers; maintain count logs and evidence trails.
- Draft and maintain SOPs, WI, and Control Matrices for internal/external audit; ensure adherence to cycle counting policy.
- Conduct periodic self-assessments, walkthroughs, and support statutory/internal audits with end‑to‑end documentation.
D. Analytics, Root Cause & Continuous Improvement
- Analyse variance trends by material/plant/storage type/vendor; perform Pareto and 5-Why / Fishbone analysis.
- Drive corrective & preventive actions (CAPA): master data fixes (UoM, rounding, BOM accuracy), process changes (backflushing, staging, returns), training.
- Track supplier and internal quality impacts on inventory accuracy; collaborate with QA for NC/CAPA closures.
- Publish dashboards and MIS: accuracy %, count completion vs plan, write‑off/write‑back values, and lead time to closure.
E. Cross‑Functional Collaboration
- Work with Production/Planning on count windows, with Procurement on supplier discrepancies, with Logistics/Stores on bin discipline, and with Finance on valuation impacts.
- Train storekeepers and shop-floor teams on counting standards (blind count, recounts, tolerances) and SAP transactions.
Required Skills & Competencies:
- SAP S/4HANA (MM/IM; exposure to WM or EWM preferred): material master, physical inventory, cycle counting, bins/HUs, movement types, document flow.
- Strong data analysis: Excel/Power Query/Power BI; variance analytics, trend & Pareto, reconciliation.
- Internal controls mindset: SoD, audit trails, evidence, approvals, and documentation rigour.
- Manufacturing domain knowledge: BOMs, backflushing, subcontracting, consignment, returns, rework/scrap.
- Excellent communication, stakeholder management, and training skills.
- Problem‑solving (5-Why, Ishikawa), lean/continuous improvement orientation.
- High ownership & integrity, detail orientation, calm under time pressure, bias for data and evidence, collaborative yet assertive.
Qualifications & Experience:
- Bachelor’s degree in commerce; MBA/PGDM (Ops/Supply Chain) is an advantage.
- 4–6 years of hands-on experience in inventory control/cycle counting in a manufacturing setup.
- Demonstrated experience running perpetual inventory and ABC-based cycle counting in SAP.
- Exposure to using digital tools like mobile-based applications for taking inventory count would be an added advantage.
