Audit Program Finished-Goods-Inventory Audit Program - AuditNet
Audit Program Finished-Goods-Inventory Audit Program - AuditNet
Audit Program Finished-Goods-Inventory Audit Program - AuditNet
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<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
Background/Purpose<br />
The purpose of this audit program is to identify specific audit procedures to be performed in<br />
conjunction with our review of the finished-goods-inventory cycle count procedures and controls<br />
over picking, staging, and shipping of finished goods inventory. The objectives of this review<br />
are to:<br />
1. Assess the effectiveness of the distribution center’s inventory cycle count program in<br />
identifying inventory shortages and other count errors.<br />
2. Test the accuracy of the book (system) to physical inventory balances at the _______<br />
distribution center.<br />
3. Observe and document the receiving and shipping processes. Assess the effectiveness of<br />
these processes in ensuring the accuracy of the inventory balances.<br />
Procedures Wkkpr<br />
Ref.<br />
Planning<br />
1. Obtain and review prior audit for this location. All<br />
2. Discuss the scope of the audit and background information with<br />
management.<br />
3. Request and obtain the following information from each<br />
distribution center location:<br />
a.) Current organization chart.<br />
b.) Cycle Count Procedures.<br />
c.) A copy of any policies on Physical <strong>Inventory</strong> processing.”<br />
d.) Copy of YTD Cycle Count Results<br />
e.) Request stock status report for ________ facility to make<br />
Cycle Count selections. Copy team on selection<br />
4. Send copy of prior year audit cycle count program<br />
documentation including count frequencies, ABC classifications<br />
etc. to the warehouse manager for review / update. The<br />
warehouse manager should be ready to discuss any changes<br />
when the audit team arrives.<br />
5. Request that the _______ warehouse manager have YTD cycle<br />
count results (unit quantity and $ value) available for review at<br />
the time of the auditor’s arrival.<br />
6. Select 3 scrap transactions processed within the fiscal year.<br />
Communicate document no. to auditors.<br />
7. Review latest month G/L to perpetual reconciliation with<br />
<strong>Finished</strong> <strong>Goods</strong> Accountant. Communicate results to auditors.<br />
8. Send copy of org. chart to auditors.<br />
Performed<br />
by
<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
Field Work:<br />
1. Meet and identify management personnel. Perform a walk<br />
through of the inventory floor.<br />
2. Inquire about all inventory locations included in the cycle count<br />
process.<br />
Procedures Wkkpr<br />
Ref.<br />
3. Inquire on status of Solutions proposed from last March audit.<br />
4. Discuss the organization. Specifically, identify the individuals<br />
responsible for the cycle count program, including those<br />
employees responsible for counting, reconciling, and reporting.<br />
5. Inquire on any changes / dismissal of warehouse staff since last<br />
March. Document the reason for any dismissals.<br />
6. Inquire on any major systems changes at ________ facility or of<br />
any major changes in the cycle count process since the last<br />
audit. Thoroughly review the documentation from the last audit<br />
and document any changes.<br />
7. Review / update of Section II. D of the last Cycle Count <strong>Audit</strong>.<br />
Review the cycle count frequencies and A,B, C classification<br />
with the warehouse manager from the last audit and update the<br />
documentation for any changes. Update the following points if<br />
applicable:<br />
a.) When was the last update of ABC codes performed?<br />
b.) Who sets ABC codes for finished goods inventory parts?<br />
c.) How are the ABC designations determined? Based on the<br />
value of the inventory? Based on the bulk of inventory?<br />
d.) When or how often are ABC calculations updated?<br />
e.) How often are A, B, and C parts counted?<br />
f.) Are there inventory items without ABC designations?<br />
i.) Obtain documentation for the most recent re-assignment of<br />
ABC classifications. Verify.<br />
8. Review reported results for the year; accuracy levels,<br />
discrepancies and adjustments:<br />
a.) What are the value ($) and quantity accuracy goals?<br />
b.) If calculated, what was the YTD accuracy level for value<br />
and quantity.<br />
c.) What are the tolerance levels for A, B, and C parts? Are<br />
they used appropriately when reporting cycle count results?<br />
d.) Inquire about the adjustment authorization procedure. How<br />
is it used? When? How is it recorded?<br />
e.) Obtain a copy of the most recent cycle count and review<br />
adjustments (if any) posted to the SAP system and to the<br />
general ledger. Review for appropriate approvals. If no<br />
Performed<br />
by
<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
adjustments from the last cycle count, look for prior<br />
adjustments and audit for appropriate approvals.<br />
f.) Review a summary of YTD cycle count differences and<br />
variances. Obtain documentation representing recording to<br />
SAP (and the General Ledger, if possible).<br />
9. Update Section III. of the last audit report via discussion of the<br />
cycle count program and observation of the warehouse<br />
personnel in the normal cycle count routine. Note the following:<br />
a.) Who coordinates the cycle count program?<br />
b.) Is there a cut off process time?<br />
c.) Who performs the cycle counts?<br />
d.) Are the counts performed blindly? Watch for the following:<br />
On 1st count, copying of perpetual count or actual counting.<br />
On 2nd count, performed by another person other than 1st<br />
counter. On 3rd count, who and how is this done (be<br />
specific)?<br />
e.) Frequency of the cycle counts? (# of times per week)<br />
f.) What time of the day are cycle counts performed?<br />
g.) Batch processing: identify the number of times per day the<br />
transactions get booked.<br />
h.) Do the number of counts vary per day? Are the number of<br />
counts to date in line with the number required to meet the<br />
objectives for number of A,B, C counts per year?<br />
Randomly select 3 A parts, and 3 B parts and verify the<br />
number of cycle counts performed on them through YTD<br />
October.<br />
i.) Is the location on schedule to meet the cycle count accuracy<br />
requirements per MFP 301 for year-end?<br />
k.) What is the acceptable error rate during the count<br />
(individually for A’s B’s and C’s)so those items are not<br />
recounted?<br />
l) Observe the cycle counter in action. Is he following the<br />
designed process?<br />
10. If possible, document the reason for known shipping errors:<br />
a) VCS 10’s to Toronto (arrived in Toronto on 10/03)<br />
b) 141’s shipped to Toronto on delivery no. 82287209.<br />
(product code 008796). (Same person / trend?)<br />
11. Document / understand what over-packing is. (according to<br />
_______, defined as consolidating multiple boxes or cartons of<br />
product into one larger box for reasons including to cut down on<br />
shipping costs, make the delivery process more user friendly for<br />
the customer, reduce risk of product damage etc. The shipping<br />
manifest system must be manually changed to produce the
<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
reduced box count on the shipping paperwork in this case as the<br />
original carton count coming over from the SAP delivery would<br />
include the separate boxes.) How common is “over-packing”?<br />
12. Does the cycle count exclude any locations from parts selection<br />
(e.g. Dock, Consignment, or Bulk areas)? Review reports to see<br />
if these are not physically counted. Are they recorded as 100%<br />
accuracy on the monthly and YTD reports?<br />
13. Internal <strong>Audit</strong> independent test counts:<br />
a.) Select at least 5 part numbers from the floor and 5 part<br />
numbers from the system. Count and compare physical<br />
count to the system. Note and document the reasons for any<br />
variances.<br />
b.) Compare accuracy levels to policy.<br />
c.) Note and document any discrepancies in accordance with the<br />
calculations from the latest audit, Sections III. and IV.<br />
d.) Verify the title of the system report used to obtain on hand<br />
units.<br />
14. Observe and thoroughly document the picking and staging<br />
process:<br />
a) What forms are generated for picking and how are they<br />
distributed. How does the shipping manifest system get the<br />
request from SAP?<br />
b) What determines which area of the dock the product will be<br />
staged at?<br />
c) What are the checks at the dock that ensure the correct<br />
product has been picked for the order? Bar code scan<br />
against the order? Independent count? If a count, who<br />
performs the count?<br />
d) What stages does the order go through in the shipping<br />
manifest system? Picked / staged / packed and loaded on<br />
truck / shipped? Are transactions executed in the shipping<br />
manifest system for each stage? What has to happen to the<br />
status of the order in the shipping manifest system to send a<br />
message to SAP to create the <strong>Goods</strong> Issue document?<br />
e) What happens to the product in SAP if a product is picked<br />
but not shipped? Is this tracked on an exception report?<br />
f) At what point is the specific truck the goods will be shipped<br />
on updated in the shipping manifest system for tracking<br />
purposes? How does the data for the specific truck get<br />
loaded into SAP? Who does the input?<br />
g) Inquire about problems with the SAP or AAT system. Any<br />
problems with the communication link between the two?<br />
Document if any.<br />
h) Observe deliveries to the staging area or dock for two orders
<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
done by two different warehouse personnel. Assess whether<br />
or not all steps documented in c) above are being followed.<br />
Reconcile the pick list generated by the shipping manifest<br />
system for the observed picks to the related sales order in<br />
SAP (VA03 screen) to ensure the shipping manifest system<br />
got the correct information passed from SAP.<br />
15. Observe the process of shipping/logistics.<br />
a.) Who determines what truck the orders should be loaded on?<br />
b.) Inquire about the use of exception reports (i.e., orders<br />
shipped through AAT, but not entered into SAP, etc.).<br />
c.) Inquire about problems with the SAP or the shipping<br />
manifest system relative to actual shipping. Document if<br />
any.<br />
d.) Document the process, including paperwork or electronic<br />
data generated, data entry performed and problems<br />
encountered.<br />
e.) Who signs / approves box counts for the various types of<br />
shipments (TL, LTL, SLC etc.)?<br />
f.) What are the controls to ensure the right product for the<br />
right order is loaded onto the right truck?<br />
g.) What data does the shipping manifest system pass on to the<br />
shipper? To the Logistics department? Does the shipper<br />
pass any data back to the shipping manifest system?<br />
h.) Select a shipment that includes over-packing. Verify that<br />
the shipping documentation includes the manual change for<br />
the revised box count.<br />
i.) For at least one shipment, ask the trucker to remove the last<br />
two pallets loaded and count the products on those two<br />
pallets and compare the counts to the shipping<br />
documentation. Note any discrepancies.<br />
j.) Select five shipments including the one from h) above<br />
which physically left the warehouse on day one of the audit.<br />
Retain all of the shipping documentation including product<br />
no. and quantities shipped. On day 2, ensure that invoices<br />
and <strong>Goods</strong> Issued were generated for the same products<br />
shipped. With the order no. or delivery no., you can research<br />
the document flow in SAP via the VA03 screen. Document<br />
any discrepancies.<br />
k.) Observe the sealing of a TL truck. Does a Bose person<br />
place the seal before the truck leaves the dock?<br />
l.) Pick a TL and an LTL order on the dock and observe it<br />
being loaded onto the truck (if possible, 1 from 14h above).<br />
Observe whether or not the trucker and warehouse person<br />
signs for the box count on each and all related shipping<br />
documentation goes with the product. Retain copies of all<br />
shipping documentation for the two orders selected.
<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
m.) Do cameras cover activity on all of the docks?<br />
n.) After return to home office, request Logistics obtain signed<br />
copy of BOL after customer delivery from the carrier for the<br />
two shipments in 15L above. Verify that the carrier and<br />
customer signs for the same number of product as was<br />
referenced in the shipping info. retained from 15L.<br />
16. Observe the process of receiving inventory into finished goods.<br />
a.) Inquire about problems with the SAP system. Document if<br />
any.<br />
b.) Inquire about communications with manufacturing plants<br />
and vendors. Are there PO’s on the system for both? Are<br />
receipts processed against the PO’s?<br />
c.) Document the process, separately for outside vendor vs.<br />
Mfg. Plant deliveries including paperwork received with the<br />
goods and paperwork or transactions processed in SAP.<br />
Document the data entry performed and problems<br />
encountered.<br />
d.) Select one receipt and observe processing into the<br />
warehouse.<br />
17. Select 3 product scrap transactions processed this fiscal year<br />
from the _________ facility inventory before the trip. Pull<br />
documentation to support the transaction and validate that the<br />
correct level of approvals were obtained in accordance with the<br />
corporate scrap policy.<br />
18. Research controls for change / delete deliveries:<br />
a) Who, outside of DC personnel has access to these<br />
commands? Do they have valid business reasons to have<br />
these commands?<br />
b) Is there a published work instruction on how to change or<br />
delete a delivery? Does it include directions to<br />
simultaneously change the shipping manifest system? =<br />
c) Interview member of the IT department to see how often<br />
Idoc error reports are reviewed. Does she have a protocol to<br />
run through to clear problem dos with the Distribution<br />
Centers?<br />
d) Run the reports for 30 days and up through 90 days? Are<br />
there any open items on the report that could cause a<br />
variance in the warehouse?
Reporting Results<br />
<strong>Audit</strong> <strong>Program</strong><br />
<strong>Finished</strong>-<strong>Goods</strong>-<strong>Inventory</strong> <strong>Audit</strong> <strong>Program</strong><br />
Procedures Wkkpr<br />
Ref.<br />
1. Summarize audit findings and discuss with local management<br />
on the last day of fieldwork. Develop and agree to proposed<br />
solutions with local management.<br />
2. Draft audit report using agreed upon format designed by<br />
Internal <strong>Audit</strong> Services and submit to <strong>Audit</strong> Manager.<br />
3. Submit draft report to local management for review and<br />
comments. Incorporate comments into report as considered<br />
appropriate.<br />
4. Finalize audit report and issue to the distribution list.<br />
Prepared by: ____Tom Clarke____________________<br />
Approved by: _________________________<br />
Performed<br />
by