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Course Overview and Foundations

Course Introduction: Purpose, Outcomes, and Use Cases

Principles of Visual Inventory Control and Two-Bin Methods

Eligibility, Data, and Right-Sizing

Deciding When Visual Review is Appropriate

Translating Demand, Lead Time, and Service Targets into Visual Triggers

Designing the Two-Bin and Visual Controls

Designing Two-Bin, Card, and Level Mark Systems

Point-of-Use Storage, Layout, and Standard Work

Operating Model, Governance, and Integration

End-to-End Replenishment Process and Roles

Governance, KPIs, Audits, and Continuous Improvement

Piloting, Scaling, and Technology Enablers

Pilot, Scale-Up, and Multi-Site Replication

Lightweight Technology to Support Visual Review

Knowledge Check and Application

Quiz: Core Concepts and Applicability

Quiz: Sizing Reorder Points and Quantities

Quiz: Designing Visual Triggers and Error-Proofing

Quiz: Point-of-Use Storage and Layout

Quiz: Process, Roles, and Replenishment Flow

Quiz: Governance, KPIs, and Audits

Quiz: Risk and Scenario Stress-Testing

Quiz: Pilot Design and Scale-Up Planning

Quiz: Technology Enablers for Visual Review

Quiz: End-to-End Operating Model Integration

Visual Review Inventory Systems: Two-Bin Design, Governance, and Scale is a practical, step-by-step course that teaches you how to implement a simple, reliable, and low-cost inventory control method for low-value, high-usage items. If you manage maintenance parts, consumables, assembly cell supplies, or stockroom essentials, this course shows you how to use visual triggers—like two-bin setups, cards, and level marks—to achieve high availability with minimal administrative overhead. You will learn when visual review outperforms periodic and continuous review systems, how to right-size bins and reorder points to service targets, and how to integrate point-of-use storage with standard work. Beyond design, the course covers end-to-end replenishment processes, role clarity, milk-run cadence, and supplier collaboration. You’ll build a governance framework with KPIs, audits, and continuous improvement routines, then create a pilot plan and scale-up playbook for multi-site replication. The result: fewer stockouts, faster replenishment, lower handling costs, and clear accountability—all without the burden of full perpetual inventory systems. By the end, you will be capable of designing error-proof triggers, setting service levels, and sustaining performance through tiered audits and lightweight technology supports like barcode cards and simple dashboards.

Visual Review Inventory Systems: Two-Bin Design, Governance, and Scale

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            <p>Visual Review Inventory Systems: Two-Bin Design, Governance, and Scale equips practitioners to design, implement, and expand a visual review control system tailored to low-value, high-usage, low-consequence items. Positioned alongside periodic and continuous review methods, the course clarifies where visual review excels—point-of-use settings such as maintenance areas, assembly cells, labs, service parts, and facilities stockrooms—by emphasizing availability, cost control, safety, and operational simplicity. Learners will build fluency in foundational concepts including two-bin mechanics, visual triggers, reorder points and quantities, and kanban-like signaling, while understanding the boundaries of applicability and the trade-offs relative to min-max, periodic count review, and perpetual systems.</p>
<p>From eligibility screening to data-driven right-sizing, the curriculum translates demand, variability, lead time, and service targets into practical visual triggers using bin sizes, cards, and level marks. Detailed design guidance covers card fields, color coding, windowed containers, shadow boards, and error-proofing to prevent early triggers, missed signals, and item mixing. The operating model is treated end-to-end: trigger-to-receipt workflows, role clarity for operators through purchasing and suppliers, cadence design, and exception handling. Learners will establish governance with KPIs such as stockout rate, trigger adherence, replenishment lead time, handling cost, and inventory turns; conduct tiered audits and control health checks; and apply countermeasures and root-cause problem solving. The program culminates in a pilot-to-scale playbook—including multi-site replication—and explores lightweight technology enablers (barcode cards, simple apps, dashboards, supplier portals) that preserve visual control while enabling data capture and incremental automation. Knowledge checks throughout reinforce core concepts, sizing calculations, trigger design, layout, process integration, governance, risk stress-testing, pilot design, and technology alignment.</p>
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