Audit of Warehouse and Inventory
Audit of Warehouse and Inventory
Audit Committee
City of West Palm Beach
401 Clematis Street
West Palm Beach, Florida
Attached is the City of West Palm Beach Internal Audit Department's report on the state of the
City’s warehouse and inventory. Although the Procurement Department has taken steps to
improve the conditions at the warehouse since we first approached them, additional opportunities
for improvement are presented in this report.
We thank the management and staff of the Procurement department for their time, information,
and cooperation during this audit.
Respectfully Submitted,
/s/ Roger Strout
City Internal Auditor
Background 4
Statement of Objective 5
Statement of Scope 6
Statement of Methodology 6
Statement of Auditing Standards 6
Audit Conclusions and Summary of Findings 6
The City of West Palm Beach warehouse is located at 1045 Charlotte Avenue; it is part of the
City Complex. It has 10,800 square feet of covered space and 10,000 square feet of open space.
Its staff, currently consisting of two (2) stores clerks, report to the Procurement Director. In the
past the warehouse was staffed by a supervisor and three stores clerks. The Procurement
Director, also referred to as the Purchasing Official, is responsible and accountable for all
supplies, materials and equipment purchased but not delivered directly to the various
departments (in other words stored in the warehouse) and is required to maintain a continuous
records of these. Also, he is required to perform any audit necessary of the inventories and
records. The Purchasing Official is also in charge of the warehouse revolving fund. The budget
of the warehouse, exclusive of the cost of inventory, was $170,784.00 for FY 2014 and the actual
cost, exclusive of the cost of inventory, was $193,100.70. Please see below for historical data:
The warehouse is responsible for providing departments with a wide variety of commonly used
items. The inventory stored there falls into two categories: general stock (for example, light
bulbs) and Public Utilities Department stock (for example, pipes). These inventories are
recorded in the City’s inventory accounts, one being reported as part of the General Fund and the
other as part of the Utilities Enterprise Fund. However, other departments, primarily Parks and
Recreation, “temporarily” store inventory on the premises, including non-stock items and
overflow. The warehouse staff does not maintain a record of these inventories. The value of the
total inventory was $782,268.21($285,671.69, general stock, or 36.52% of the total, and
$496,596.52, Public Utilities stock, 63.48% of the total) as of September 30th 2014. Please see
below for historical data.
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Value of Public
Value of
Value of Public Utilities
General Stock
September Total Value of Utilities Department
as a
30th Inventory General Stock Department Stock as a
Percentage of
Stock Percentage of
the Total
the Total
a b c=(b/a)*100 d E=(d/a)*100
This audit was initiated as a result of an annual risk assessment and included in the Audit
Department’s approved FY2014 Audit Plan.
It is important to note that the new Purchasing Director was aware of the significant needs at the
City run warehouse and welcomed this audit as an important analysis tool to help chart a new
direction for the warehouse.
Statement of Objectives
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Statement of Scope
The audit period was October 1, 2012 through September 30, 2013. However, based on the work
performed during the preliminary survey and the assessments of risk, the audit period varied
depending on the audit objective. The audit included examinations of procedures, controls,
transactions and records associated with the City’s warehouse and inventories.
Statement of Methodology
We conducted this audit in accordance with Generally Accepted Government Auditing Standards
(GAGAS). Those standards require that we plan and perform the audit to obtain sufficient,
appropriate evidence to provide a reasonable basis for our findings and conclusions based on our
audit objectives. We believe that the evidence obtained provides a reasonable basis for our
findings and conclusions based on our audit objectives.
Based upon our interviews, analytics, and the audit opportunities for improvement noted below,
we conclude that the Procurement Department should consider performing a restructuring of the
warehouse operation.
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11. Inventory counts are not performed.
12. City departments temporarily storing items at the warehouse are
not required to complete non-stock inventory records.
13. Inventory is not regularly examined for obsolescence.
Criteria
According to the Occupational Safety and Health Administration (OSHA), the fatal injury rate
for the warehousing industry is higher than the national average for all industries. There are
numerous potential hazards in such an environment including unsafe use of forklifts, improper
stacking of products, failure to use proper personal protective equipment, improper lifting, etc.
However, some of the most detrimental ones relate to the facilities themselves including exposed
or open loading dock doors, cluttered isles, improper lighting, improper ventilation, improper air
conditioning, etc.
Condition
The warehouse is in state of total disrepair. It is dark and humid, it is not air conditioned, and
there are no emergency lights. We noted that items are being temporarily stored between the
aisles making it easy for the staff to trip over. Years ago the City began the implementation of a
bar code system, but the project was inadequately funded and was abandoned mid-way through
implementation. The roof has not been repaired recently and in rainy weather, especially during
hard rain, leaks through the old sky lights. The loading dock’s metal plate has begun to separate
from the concrete becoming a tripping hazard. In addition, we noted that the railing on the stairs
was unstable; it had separated from the concrete. Also, there was vegetation growing where the
concrete had cracked. During our tour of the warehouse yard, we noted significant inventory
placed outside exposed to the weather, which appeared to not have been moved in years.
Finally, the equipment assigned to the warehouse, including the two forklifts and the two
delivery vans, appear to be quiet old. One of the fork lifts was put into service twenty (20) years
ago in the summer of 1994. Please see the photographs in the Appendix A.
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Cause
Over the past several years, the warehouse staff has shrunk from four (4), including one
supervisor responsible for ordering, processing documentation, billing, etc., and three (3) store
clerks, to just two clerks with the same number of responsibilities. In the absence of automation,
the daily tasks of the store clerks have become overwhelming not allowing them to maintain the
facility. In addition, there has been no money allocated for repairs and/or improvements.
Effect
The current conditions could result in significant damage to the inventory and unsafe conditions
for the two clerks.
Recommendation
We recommend that the Procurement Director addresses these conditions with Administration
and obtain emergency funding to allow him to bring the facility up to appropriate warehouse
standards.
Please note that implementing a bar coding system will be most helpful to the warehouse staff.
Utilizing a network of hardware and software to automate data collection where hand recording
is neither timely nor cost effective will clear time for them to address other pending issues within
the facility. We recommend that a team be formed including the two warehouse clerks and IT
employees to evaluate the situation, research available options and implement the one best suited
for this warehouse environment.
We also noted during our tour of the City of Miami warehouse that its manager utilizes the
services of other City employees familiar with inventory and the inventory process during peak
times like mornings when department representatives pick up their orders. These are usually
tradesmen who have availability for a limited time. Their help is essential since it relieves the
warehouse staff and allows them to focus on other tasks. Management may wish to consider this
approach to address the warehouse staffing issue further discussed in our finding No. 8.
Management Response
We concur with this recommendation. We will immediately begin to address safety issues at the
warehouse. The Risk Manager has already conducted a site visit and has prepared a list of items
that are currently being addressed. See Appendix B. A cross-functional team has been formed
to implement process improvements and develop a long term plan to ensure the warehouse is
operated in an efficient manner. The warehouse will be transitioned to the Utilities Department
by September 30, 2015 and many of the best practices they have instituted will be duplicated. A
budget for capital improvements will be developed and submitted for the 2016 capital
improvement plan.
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2) Safeguarding of Inventory – Gate and Doors
The gate and doors leading into the warehouse are kept open throughout the day.
Criteria
According to the Committee of Sponsoring Organizations (COSO) of the Treadway
Commission:
The first step toward ensuring that the City’s inventory is protected is ensuring that access to the
facility is limited.
Condition
During our tour of the warehouse, we noted that the gate was open. Upon inquiry of the
warehouse staff, we noted that it is normally open (from 07:00 am to 04:00 pm Monday through
Friday).
Furthermore, there are a total of five (5) bay doors (4 leading in the main warehouse and 1
leading into the adjacent concrete room), all are kept unlocked during business hours. There are
four (4) push bar style doors leading into the warehouse, only one is keyed. A hand recognition
device was installed at one of these doors and operated until ten (10) years ago when
management declined to spend money to fix it. There is one (1) regular door leading into the
concrete room, which is kept open during business hours.
Cause
The remote gate controller, installed following a recommendation made by the Internal Audit
Department in 2000, is broken and therefore not utilized. The staff manually opens the gate in
the morning and keeps it open, and manually closes the gate at night. A chain with a padlock is
used to keep the gate closed during the night. The remote gate controller is also considered an
inconvenience by the staff since someone needs to stay in the office all the time in case an
employee calls and requests access.
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Effect
This presents little to no opportunity to control who enters and leaves the premises. Since a
considerable amount of inventory is stored in the open, items may be removed without the
knowledge of the warehouse staff.
Recommendation
We recommend that the Procurement Department research and obtain an entry control system,
which allows City employees to enter the warehouse via a swipe of their ID cards. The number
of people entering can be further reduced by granting access to select employees. The use of a
system such as this will also allow for the identification of the people who enter the warehouse.
Also, the system should allow outside delivery personnel to call, for example the Fleet office,
and be allowed entry.
Finally, we recommend that the doors are kept locked at all times and opened upon request.
Management Response
We agree with this recommendation. An entry control system to the warehouse will be
researched and a budget request will be made as part of the 2016 Capital improvement plan.
Criteria
Once access to the facilities is limited, it is common for a business to use additional precautions
including alarms, cameras, guards, etc.
Condition
Upon inquiry of the warehouse staff, we noted that there is no alarm system installed. There is a
security guard patrolling the City complex area between 6pm and 6am and there are also
cameras. The recordings from these cameras are saved for thirty (30) days and then recorded
over. They are not equipped with night vision.
Cause
The cameras were installed over ten (10) years ago and have not received any additional
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investment. Upon inquiry, we noted that the footage is not actively monitored. Instead, it is only
examined if management is alerted to an issue.
Effect
The possibility exists that in the absence of an alarm an intruder may circumvent the security and
make his/her way into the warehouse. Although the cameras may act as a deterrent, they do not
appear to have the necessary range of coverage.
Recommendation
We recommend that the Procurement Department, which is in charge of the warehouse, arrange
for the installation of an alarm system for the warehouse building. Security alarms on doors can
both sound off in case of a break-in and alert police.
Management Response
The installation of an alarm system will be considered as we develop an improvement plan for
the warehouse operations.
Criteria
Best practices indicate that a log be kept of visitors entering the facility.
Condition
Upon inquiry of the warehouse staff, we noted that there is no log of who visits the warehouse
throughout the course of a day.
Cause
Staff feels that the Warehouse Requisition Forms serve the same purpose.
Effect
A visitor log in itself cannot prevent misappropriation of assets; however, it acts as an additional
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deterrent.
Recommendation
We recommend that the warehouse staff require that all non-city employee visitors sign in on a
visitor’s log. The log should include not only their name, but the organization they represent and
the time of arrival and departure.
Management Response
We agree with this recommendation. A visitors’ log was put into effect the beginning of
February.
Criteria
Best practices indicate that policies and procedures are typically custom designed for the
particular environment, documented in writing and communicated to personnel throughout the
organization.
Condition
The warehouse policies and procedures are outdated and do not reflect the current staffing and
process. Also, they are not communicated to personnel including personnel outside of the
Purchasing Department.
Cause
The warehouse supervisor left the City in 2010. His position has not been filled and since he is
the person best suited to update the policies and procedures, this has not been done.
Effect
There is no clearly documented guidance to warehouse personnel and any other personnel supporting this
function.
Recommendation
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We recommend that the Procurement Director or his designee work with the two store clerks to
develop policies and procedures suitable for this warehouse environment. In addition, all
employees who utilize the services of the warehouse should receive a copy of the policy and
procedure manual, and sign forms acknowledging receipt of the manual. Training should follow
the written guidelines. Each employee should be held accountable for his or her role in carrying
out inventory policies and procedures.
Management Response
We concur with this recommendation to develop a policies and procedures manual. We will
update the Policy and Procedures by September 30, 2015.
Inventory reports traditionally used to monitor inventory levels are not utilized.
Criteria
Per the City of West Palm Beach Procurement Procedures, a minimum/maximum report is used
to alert the Warehouse Supervisor of the impending depletion of certain items. The report
specifies which items and the quantities to be re-ordered once the quantities on hand reach a pre-
determined level. Also, per the Procedures, a Transaction Quantity Historical Summary report,
which provides specific information on the movement of inventory (receipts and issuances), is
used in tandem with the minimum/maximum report. These reports will assist the Supervisor in
making a determination as to when to re-order and avoid carrying excess inventories.
Condition
Upon inquiry, the warehouse staff informed us that this is not being done. Instead, both
employees take notes as to what is being depleted and needs to be re-ordered as they perform
their daily duties. Then, orders are placed.
Cause
The warehouse supervisor left the City in 2010 and the clerks were not trained to run these
reports.
Effect
There is a risk that the warehouse may carry excessive quantities to avoid running out of certain
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items thus resulting in higher cost to the City.
Recommendation
We recommend that staff is trained to utilize these reports or similar reports within the Oracle
system.
Management Response
We concur with this recommendation to provide training to staff. We will assess the
competencies and coordinate training with the IT Department.
7) Purchasing Contracts
Criteria
Pre negotiated contracts provide convenience, efficiency, and reduced costs. More specifically
they:
Condition
Upon inquiry, the warehouse staff informed us that before ordering from any vendor a quote is
first obtained since many contracts have expired and this is the one sure way to obtain up-to-date
pricing.
Cause
Contracts have not been renewed since the City has been allowed by vendors to “piggy back”
other governmental entities’ contracts.
Effect
There is a risk that the prices may be higher since the absence of a contract does not always
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allow the City to leverage buying power through volume purchasing. In addition, this can lead to
increased administrative costs due to the repetitive acquisition efforts of staff.
Recommendation
We recommend that the Procurement Department ensure that all vendor contracts are current.
Management Response
We concur with this recommendation to update all contracts with vendors; we are currently
implementing this recommendation. Completion date for all contracts with vendors will be
September 30, 2015.
8) Segregation of Duties
Criteria
Segregating employee duties is an important internal control system feature in any environment
including inventory management. Dividing specific duties between employees helps minimize
risk of fraud, and maximize inventory and supply protection.
Inventory ordering, receiving, and record keeping functions should be performed by separate
team members.
Condition
The same employee places orders, receives inventory, keeps records, issues inventory and
updates inventory in Oracle, etc.
Cause
Over the past several years, the warehouse staff has shrunk from four (4), including one
supervisor responsible for ordering, processing documentation, billing, etc., and three (2) store
clerks, to just two clerks. The supervisory position has not been filled forcing staff to perform
incompatible tasks.
Effect
There is a risk that inventory may be misappropriated.
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Recommendation
We recommend that tasks are divided between the warehouse staff and Procurement
Department’s staff in such a way that one employee should be in charge of and authorized to
complete the ordering function, another should receive inventory and inspect it, yet another
should be in charge of the record keeping.
The Procurement Department may also wish to consider utilizing the services of other City
employees similar to the way the City of Miami does, as outlined in our recommendation for
improvement No. 1.
Management Response
We concur with this recommendation for segregation of responsibilities for internal control
purposes. This will be achieved upon the transfer to and consolidation of warehouse operations
with the Utilities Department. This should be completed by September 30, 2015.
9) Receiving Documentation
Criteria
Best practices indicate that purchase orders without quantities ordered displayed should be used
during receiving.
Condition
Upon inquiry, the warehouse staff informed us that they actually rely on visual inspection and
the vendor’s bill of lading/packing slip when determining if the correct items and/or correct
quantities were shipped.
Cause
The warehouse supervisor left the City in 2010.
Effect
There is a risk that an incorrect shipment may be accepted.
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Recommendation
We recommend that the warehouse staff begin to utilize purchase orders without quantities
ordered displayed during receiving.
Management Response
Criteria
Per the City of West Palm Beach Procurement Procedures, Warehouse Requisition Forms must
be completed in full and signed by an authorized department or division head from the respective
department prior to any item(s) being issued out of inventory.
Condition
Upon inquiry, the warehouse staff informed us that often they would have to complete the
requisition, fill out the stock numbers, etc.
Cause
Many employees are not familiar with the catalogue and find it difficult to locate the items they
need.
Effect
Completing requisition forms for requesting departments is extremely time consuming for the
two warehouse clerks that already have an overwhelming amount of responsibilities.
Recommendation
We recommend that the Procurement Department train City employees how to requisition items
from the catalogue. This training should be done periodically.
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Management Response
We concur with this recommendation regarding training of city employees on how to use the
catalogue. We will implement training for warehouse requisitions on July 1, 2015.
Criteria
Per the City of West Palm Beach Procurement Procedures, a cycle count listing should be
generated weekly, randomly selecting inventory items to be counted. Additionally, an outside
firm may be retained to conduct an annual physical inventory.
Condition
In the past, cycle counts were performed weekly. The discrepancy reports resulting from these
cycle counts were kept by the Procurement Division (now the Purchasing Department).
Currently, cycle counts are not performed. Also, monthly, the perpetual inventory records were
reconciled to the general ledger. Currently, this is only done once a year.
In the past, an outside firm was hired to do a count of the entire inventory once a year. Upon
inquiry, a complete count has not been conducted since 2012. This last count was conducted
entirely by City employees, including the two store clerks.
Cause
This is not being done due to shortness of staff and absence of automation.
Effect
If inventory counts are not conducted regularly, differences between the physical inventory and
the inventory records can occur and remain undetected. In addition, misappropriation of stock
could occur without timely detection.
Recommendation
We recommend that the Procurement Department re-initiates cycle counts and complete yearly
inventory counts to help ensure that records are brought up-to-date and are complete and
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accurate. The yearly inventory counts should be done using personnel outside of the
Procurement Department if possible if an outside firm cannot be contracted. In addition, the
perpetual inventory should be reconciled monthly to the general ledger.
Management Response
We concur with this recommendation to re-initiate cycle counts and complete yearly inventory
counts. We will conduct a physical inventory and reconciliation to our accounting records prior
to transfer of operations to the Utilities Department. We anticipate a completion date by July
2015.
Departments temporarily storing items at the warehouse are not required to complete non-stock
inventory forms.
Criteria
Best practices indicate that a complete list of all inventory stored in the warehouse should be
maintained.
Condition
Upon inquiry of the warehouse staff, we noted that many departments keep inventory on the
premises temporarily. However, they are not required to fill out a non-stock inventory form
prior to leaving their items for storage.
Cause
Over the past several years, the warehouse staff has shrunk from three (3), including one
supervisor, to two (2) store clerks with the same number of responsibilities. This has not been a
priority in light of all the other tasks they are expected to accomplish each day.
Effect
In the absence of a list of all items on hand, the ability to identify shrinkage, losses or other
misappropriation is limited. Additionally, hazardous materials may be stored without the
knowledge of the warehouse staff.
Recommendation
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We recommend that records be kept of all the items stored at the warehouse.
Management Response
We concur with this recommendation to keep records of all items stored at the warehouse. We
will also develop a policy to address non-stock items.
Criteria
Best practices indicate that stored inventory be examined regularly to identify obsolete items.
Condition
Upon inquiry of the warehouse staff, general inventory items rarely become obsolete and thus
are not examined. Also, utilities inventory items are seldom examined and the ones that have
become obsolete are sold for scrap. Overall, it is up to the Procurement Director or his designee
to direct staff regarding inventory obsolescence identification and disposal procedures; however,
no formal obsolescence identification and disposal process and procedure has been provided or
carried out.
Cause
It was a practice to examine inventory for obsolescence in the past, however, on several
occasions, items that were disposed of were then requested and the practice was discontinued.
Effect
Storing obsolete items in the warehouse takes up space that may otherwise be used for storage of
currently used items. In addition, if obsolete items have any salvage value, identifying and
disposing of them may generate additional funds for the City.
Recommendation
We recommend that the Purchasing Department implement procedures for periodic review of
inventory records and physical inventory to identify items that may be obsolete and dispose of
them in the most appropriate and timely manner. We also recommend that those with technical
expertise relating to specific inventory items be consulting when evaluating items for
obsolescence.
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Management Response
We concur with this recommendation. Obsolete items will be identified during the upcoming
physical inventory and will be appropriately disposed of no later than September 30, 2015.
Criteria
According to the Government Accountability Office (GAO), managing the acquisition, storage,
and distribution of inventory is critical to controlling cost, operational efficiency, and mission
readiness. Physical controls and accountability reduce the risk of (1) undetected theft and loss,
(2) unexpected shortages of critical items, and (3) unnecessary purchases of items already on
hand. These controls improve visibility and accountability over the inventory, which help ensure
continuation of operations, increased productivity, and improved storage and control of excess or
obsolete stock.
Cause
Please refer to the opportunities for improvement recommended in findings No. 1 through No.
13. The City’s warehouse operation has been in need of greater funding for extended periods of
time.
Effect
Recommendation
In light of the opportunities for improvement (No. 1 to No. 13), our visits to the Palm Beach
County warehouse and the City of Miami warehouse, and independent research, we would like to
recommend several different options for management’s consideration.
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A. The Purchasing Department should prioritize the significant issues currently affecting the
warehouse. The Purchasing Director should request that emergency funding be directed
to his Department in order to implement the most pressing warehouse needs. Items that
may directly affect the state of the inventory and the well-being of the warehouse staff
and visitors should be addressed first followed by the installation of a bar code system to
automate the process and make it more efficient.
B. The Purchasing Department may wish to request that the Public Utilities Department
takes possession of all Public Utilities related inventory and move it into one of the
Utilities Department’s several warehouses. Then, the remaining inventory should be
evaluated for turn over activity and potential elimination or user direct purchase
opportunities. The remaining inventory may be moved to a smaller facility.
C. As an alternative, the Purchasing Department may wish to place control of the warehouse
and all inventories with the Public Utilities Department which has more in-house
warehouse expertise. For example, the Utilities Department stores significant inventories
at its East Central Regional Reclamation Facility (ECRWRF) and the City’s water plant.
D. The Administration may also wish to consider an arrangement with the Palm Beach
County (County) warehouse which performs similar services and appears to have excess
capacity at their new facility. Administration may wish to enter into a service agreement
with the County. During the Internal Audit Department’s tour, we noted that the County
carries similar inventory and that their delivery vehicles service County structures in
close proximity to many City of West Palm Beach locations.
E. Finally, the warehouse operation could be outsourced to a third party vendor who
specializes in inventory management. There are many companies, which offer this type
of service. From “middle man” companies that put their clients in touch with pre-
screened vendors based on their needs determined by a questionnaire to actual third party
logistics companies. There are a number of different choices available to Administration
if this path is chosen.
Management Response
We agree with option C. City Administration has already made the determination to place
control of the warehouse with the Public Utilities Department. This consolidation makes sense
as the Utilities Department has an experienced warehouse supervisor, 70% of the warehouse
items are assigned to the Utilities Department, greater efficiencies can be achieved and proper
separation of duties can be instituted without adding more staff. The Procurement Director
along with the cross-functional team will work with Utilities staff to enable a smooth and
efficient transition no later than September 30, 2015.
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APPENDIX A
City of West Palm Beach Warehouse, along with
photos taken at other County/City Warehouses
for comparison purposes.
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Palm Beach County Warehouse
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City of Miami Warehouse
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APPENDIX B
Warehouse Safety Remediation Status Report
02/17/2015
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