SAMPLE COMPANY Page 1 of 4 SOP # 15-2 Revision: 0 Prepared by: _ Effective Date: Approved by: _ Title: PHYSICAL INVENTORY PROCEDURES Purpose: This procedure is intended to outline the actions to be taken to enable an accurate physical count of inventory items. Scope: This procedure applies to all inventory items including raw materials/parts, work in process and finished goods contained in the areas of Manufacturing, Storage/warehouse, Engineering, Showrooms or consigned out for demonstrations or service. Procedures: 1.0 Timing 1.1 The physical inventory will be taken at year-end or during the immediately following business days. The starting time will be determined by the production management and controller and communicated to all employees involved with the Physical Inventory. 2.0 Cleaning and Organization of Inventory Areas 2.1 Prior to beginning the physical counting process all areas containing inventory are to be cleaned and organized to their optimal standard. 2.2 All loose inventory items should be removed from work stations or machines and neatly placed or stored into bins, shelves, racks, etc. Identical parts that are used in multiple locations should (if practical) be combined into one storage area to facilitate ease of record keeping. After grouping and organizing identical parts (i.e., on shelves or bins), then all inventory items should be reasonably separated and identified/labeled to avoid any confusion between similar looking or types of parts. 2.3 All non-inventory, defective or obsolete parts should be clearly segregated from inventory items to be counted. These items should also be visibly marked or indicated to their nature (i.e., "Non-Inventory - Do Not Count" "Defective", etc.). PHYSICAL INVENTORY PROCEDURES Page 2 of 4 2.4 All count areas (shelves, benches, storage, etc.) should be labeled by an Alphanumeric code for ease in identification of location. For example the first shelf unit would be labeled A with individual rows numbered from top to bottom A1, A2, A3, etc. Alphabetical characters should be used from A to Z and then proceed to double or Triple Alpha characters (i.e. AA, AB, AC or AAA, AAB) until all areas have been uniquely assigned a location code. 3.0 Year End Cut-Off 3.1 To adequately control cut-off of inventory transactions for purchases (receiving) and sales (shipments) operations will be completely shut down. Any goods received after year-end but prior to completion of Physical Inventory will be kept in the receiving area and will not be unpacked or received in any way. All finished goods should be kept in the finished Goods Staging area and should not be packed or shipped until after completion of the physical inventory. 3.2 To document year-end cut-off, the last five (5) sequential shipping documents and receiving reports will be copied and provided to the company's external auditors. 4.0 Counting Procedures and Instructions 4.1 To facilitate an efficient counting and verification process, count teams consisting of two individuals should be formed by the Inventory Control Manager. At least one individual from each team should be knowledgeable about the inventory items to be counted. A master floor plan of areas containing inventory items should be prepared with areas color coded by count team. Individual Team counting assignments with the date and approximate starting time for the Physical count should be prepared and distributed to the teams along with these counting procedures prior to year-end. 4.2 A pre-count meeting should be held by the Inventory Control Manager and the company's Controller with all count team members to review counting procedures/instructions and answer any questions. Each count team should be started by the Inventory Control Manger and should be periodically observed by the Inventory Control Manager to assure that instructions are being complied with in the counting and listing process. 4.3 A package of sequential pre-numbered inventory sheets will be prepared by the I.C. Manager and distributed to the Count Teams according to their assignment. Upon completion, count sheets are to be returned to the Inventory Control Manager and should all be accounted for (i.e., used, unused, voided). PHYSICAL INVENTORY PROCEDURES Page 3 of 4 The inventory sheets will be pre-printed for current part #'s maintained by the company. Blank inventory sheets will also be provided to list any inventory items not found on the pre-printed sheets. The format of the count sheets should contain a Heading with the name of the Company, Date of Physical count, Sequential Page number and Description of Page (i.e., Physical Inventory Count Sheet). Individual Column Headings should be prepared with Part #, Description, Location, Quantity and Initials of person recording the count. 4.4 Count teams should count items in their assigned area in a logical, sequential (non-random) fashion to avoid any chance of missing or duplicating counting of items. General rules of procession should be followed (i.e., Left to Right, Top to Bottom and Front to Back) After counting a distinguishable area (i.e., shelf unit, wall, box, etc.) a yellow tag label should be attached to indicate that the area has been counted. Inventory comprised of small, numerous components that would involve tedious counting and also have a very low dollar value (i.e., screws, nuts, fasteners, etc.) will be reviewed with the Inventory Control Manager and if deemed appropriate will be estimated as to volume in round numbers (i.e., 250, 500, etc.). The estimated # will be recorded on the Count Sheet but must be notated by the symbol "Est." before the number to indicate that the value was not obtained by a true physical count. As an alternate, these items can be weighed using a scale and counting a representative sample (i.e., 25 screws) to determine a weight/count ratio for this item and using this ratio against the total weight of the items to determine a count. If this method is utilized a "W" symbol should be noted before the number on the Count Sheet to indicate that the value was obtained through a weighed estimate and not by a true physical count. 4.5 Finished Goods and work in process will be counted and recorded on individual sheets. Finished Goods will be noted by Model # and multiplied by the respective Bill of Materials to determine the value of individual part #'s. Work in process will be noted by Model # and Estimate of completion level in Percentage terms (i.e., 75%). This percentage will then be used with the respective Bill of Materials to determine the value of the inventory contained in the item. 4.6 Inventory that is out of the Company including Sales Demonstration units, Service loaners or consigned should be recorded on the Company's Request from Inventory Forms. These forms should be copied as backup and for confirmation purposes and the inventory items counted and included with the physical count. PHYSICAL INVENTORY PROCEDURES Page 4 of 4 5.0 Master Inventory and Pricing Report 5.1 Upon completion of the Physical Count and receipt of Count Sheets, the Inventory Control Manager will prepare a Master Inventory Record for all inventory items with the total count for each item obtained from all locations. The report will be divided into three sections, 1; Raw Materials, 2; Work in Process, 3; Finished Goods. 5.2 The report will also contain the standard cost for each item and the extended value (Qty. X Std. Cost) for each item with column totals by the above three categories and a grand total of all inventory value. 5.3 Upon completion of the report by the Inventory Control Manager, the report along with all backup documents will be forwarded to the Controller for review and verification and subsequent testing and analysis by the company's independent auditors.