COURSE OVERVIEW:
Welcome to the Stock Control & Reordering in Automotive Retail & Service course. This program has been developed to provide you with the knowledge, systems, and operational strategies required to manage automotive stock accurately, efficiently, and profitably across service and retail environments.
Effective stock control plays a critical role in ensuring seamless workshop operations, timely customer service, and retail success. This course begins by exploring how inventory management supports productivity, minimises downtime, and enhances service outcomes. Participants will examine the impact of stock shortages, overstocking, and inaccurate records on customer satisfaction, labour efficiency, and financial performance, while clarifying the responsibilities of those involved in parts handling, stock control, and reordering processes.
Understanding the different types of inventory is essential for managing stock effectively. This section introduces the classification of parts and consumables—such as service parts, accessories, fluids, and tools—into fast-moving, slow-moving, and seasonal categories. Participants will learn how to distinguish between stock held for resale, repairs, display, and workshop use, and why each category requires tailored controls and replenishment strategies.
A structured inventory system is the foundation of accurate stock control. This section explores how to set up manual or digital inventory methods, assign barcodes and part numbers, and design logical storage layouts. Emphasis is placed on accessibility, traceability, and reducing handling time through efficient part placement and categorisation.
Accurate receiving processes are essential to ensure stock integrity. This section covers how to verify incoming deliveries against purchase orders and invoices, inspect for damage or discrepancies, and enter stock correctly into the inventory system. Effective checking at the point of receipt helps prevent future inventory and invoicing errors.
Labelling and organisation support fast retrieval and prevent mix-ups. This section outlines techniques for labelling shelves, bins, and part containers in a way that reflects stock usage and frequency. FIFO (First-In-First-Out) practices are introduced to ensure older stock is used first, reducing spoilage and obsolescence.
Tracking stock usage enables informed purchasing and planning. This section discusses how to monitor parts consumption across departments, jobs, and locations. It introduces turnover rate calculations and reporting methods to identify high-demand items, spot ageing or obsolete stock, and refine ordering patterns.
Regular stocktakes maintain system accuracy and support loss prevention. This section introduces scheduled and rolling stocktaking procedures, team responsibilities, and reconciliation methods. Participants will learn how to plan, document, and resolve discrepancies between physical stock and system data.
Stock discrepancies must be managed transparently. This section addresses common causes of variances—including theft, misplacement, and write-offs—and provides processes for recording stock adjustments. Guidelines for reporting significant variances to management or auditors are also covered to meet governance obligations.
Reorder levels must be tailored to each item’s usage profile. This section explores how to calculate minimum and maximum stock levels using demand rates, lead times, and safety stock considerations. Strategies for flagging critical parts and ensuring availability of time-sensitive components are also discussed.
Ordering must be accurate and timely to maintain stock flow. This section examines how to generate requisitions, request quotes, and prepare formal purchase orders. Participants will learn how to communicate effectively with suppliers to confirm availability, lead times, and delivery expectations.
Supplier relationships influence pricing, availability, and delivery reliability. This section explores how to manage preferred supplier lists, negotiate favourable terms, monitor performance, and ensure the supplier base aligns with operational needs and quality standards.
Returns, warranties, and core parts require careful administration. This section explains how to process returns for faulty or excess items, manage credits and replacements, and handle documentation related to core charges. Effective return procedures help recover value and minimise write-offs.
Integration between inventory and workshop systems streamlines stock control. This section covers how to link parts usage to job cards and service records, automate reordering, and synchronise inventory data with invoicing and reporting systems to reduce manual errors and administrative workload.
Managing stock across multiple locations presents coordination challenges. This section outlines best practices for inter-branch stock transfers, shared inventory tracking, and maintaining consistency in part codes, descriptions, and labelling to avoid confusion and delays across sites.
Consumables are easily overlooked yet vital to daily operations. This section explains how to track, reorder, and control items such as lubricants, adhesives, fasteners, and shop supplies. Strategies for reducing wastage and preventing theft or loss in shared areas are also provided.
Overstocking and stockouts disrupt efficiency and profitability. This section helps participants recognise stock movement trends, anticipate seasonal demand changes, and adjust forecasts to avoid costly overstocking or missed sales due to unavailability.
Inventory performance must be reviewed for financial sustainability. This section outlines how to calculate holding costs, assess gross margins on stocked items, and identify slow-moving or dead stock that ties up capital and shelf space unnecessarily.
Stock control processes must be regularly reviewed and refined. This section promotes the use of audits, team feedback, and data reports to identify areas for improvement. Participants will explore how to update SOPs, improve training, and modernise systems to support evolving workshop and retail needs.
By the end of this course, you will be equipped with the systems knowledge, procedural discipline, and analytical tools required to manage inventory effectively across automotive retail and service operations—ensuring availability, efficiency, and profitability in a dynamic, customer-focused environment.
Each section is complemented with examples to illustrate the concepts and techniques discussed.
LEARNING OUTCOMES:
By the end of this course, you will be able to understand the following topics:
1. Introduction to Stock Control in Automotive Operations
- The role of stock control in service and retail performance
- Impacts of poor stock control on productivity and customer service
- Overview of key responsibilities in parts, inventory, and reordering
2. Understanding Types of Automotive Inventory
- Differentiating between fast-moving, slow-moving, and seasonal stock
- Categories: service parts, accessories, fluids, and consumables
- Stock held for repair, resale, display, and workshop use
3. Setting Up an Effective Inventory System
- Choosing between manual and digital stock control methods
- Assigning part numbers, barcodes, and locations
- Creating an organised and logical storage layout
4. Receiving and Checking Incoming Stock
- Verifying deliveries against invoices and purchase orders
- Inspecting parts for damage or defects
- Recording new stock in the inventory system
5. Organising and Labelling Stock for Easy Access
- Labelling shelves, bins, and parts accurately
- Separating stock by category, use, or frequency
- Implementing FIFO (First-In-First-Out) practices
6. Monitoring Stock Usage and Turnover Rates
- Tracking part consumption trends across jobs and departments
- Identifying high-usage items and obsolete inventory
- Using turnover ratios to inform purchasing decisions
7. Conducting Stocktakes and Cycle Counts
- Planning periodic stock audits or rolling stocktakes
- Assigning teams and documenting discrepancies
- Reconciling system data with physical counts
8. Managing Stock Adjustments and Discrepancies
- Identifying causes of shrinkage: theft, misplacement, write-offs
- Recording adjustments with justification
- Reporting major losses to management or auditors
9. Establishing Minimum and Maximum Stock Levels
- Setting reorder points for each key item
- Using lead time, demand rate, and safety stock in calculations
- Flagging critical parts for higher availability
10. Creating and Issuing Requisitions and Orders
- Preparing internal requisitions or purchase requests
- Contacting suppliers for quotes, availability, and lead times
- Placing formal orders via system or email
11. Managing Supplier Relationships and Terms
- Maintaining an approved supplier list
- Negotiating pricing, delivery schedules, and returns
- Reviewing supplier performance and reliability
12. Handling Returns, Warranty, and Core Parts
- Processing faulty or excess stock returns
- Managing credits, replacements, and core charges
- Documenting return authorisations and paperwork
13. Integrating Stock Control with Workshop Management Systems
- Linking parts usage to job cards and repair orders
- Automating reordering through inventory software
- Syncing sales, inventory, and reporting systems
14. Managing Stock Across Multiple Locations
- Coordinating inventory between stores, workshops, or warehouses
- Transferring stock and tracking inter-branch movement
- Maintaining consistency in stock codes and labelling
15. Controlling Consumables and Shop Supplies
- Tracking items like lubricants, cleaners, rags, and fasteners
- Setting usage limits and reordering intervals
- Reducing waste and stock loss in shared areas
16. Preventing Overstocking and Stockouts
- Recognising patterns that lead to surplus or shortages
- Adjusting forecasts based on seasonality or campaigns
- Monitoring slow movers and ageing stock
17. Analysing Stock Performance and Profitability
- Measuring inventory holding costs and order efficiency
- Reviewing margins on stocked items
- Identifying dead stock and low-performing SKUs
18. Reviewing and Improving Stock Control Practices
- Conducting regular process reviews and staff training
- Updating SOPs and inventory policies
- Using feedback and system reports for continuous improvement
COURSE DURATION:
The typical duration of this course is approximately 2-3 hours to complete. Your enrolment is Valid for 12 Months. Start anytime and study at your own pace.
COURSE REQUIREMENTS:
You must have access to a computer or any mobile device with Adobe Acrobat Reader (free PDF Viewer) installed, to complete this course.
COURSE DELIVERY:
Purchase and download course content.
ASSESSMENT:
A simple 10-question true or false quiz with Unlimited Submission Attempts.
CERTIFICATION:
Upon course completion, you will receive a customised digital “Certificate of Completion”.