inventory management of escorts company
TRANSCRIPT
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Final project report on
Inventory management system
CONDUCTED AT:
FEDERAL MOGUL GOETZE (INDIA) LIMITED,
BAHADURGARH, PATIALA
SUBMITTED TO:
Punjab Technical University Jalandhar
In the partial fulfillment of the requirement for the degree of MBA(Master of business Administration)
(2008-10)
Supervised by SUBMITTED BY
MS.KAVITA CHOPRA POOJA RANIMBA 4THSEMESTER (financ
Universities roll no-8080331707
DESH BHAGAT INSTITUTE OF MANAGEMENT AND COMPUTER SCIENCE
http://www.federal-mogul.com/en/http://www.federal-mogul.com/en/ -
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CONTENTS_________________________________________________________________
Acknowledgement
Declaration
Certificate
An Introduction
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SECTION-A: A BRIEF OVERVIEW OF FEDERAL MOGUL GOETZ
(INDIA) LIMITED, PATIALA
An Introduction to GIL
Important Products
History Milestones
Members of Management Body
A Chronological View of product Information
Social Activities
Market Share
Significance of Logo
Primary and Secondary Objectives
Vision
Mission
Important Customers
Japanese Practices of 5-S
Organizational Set up Organizational Chart
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SECTION B: INTRODUCTION TO INVENTORY MANAGEMEN
AND INVENTORY MANAGEMENT IN FMGIL
Introduction to Inventory Management
Inventory Management Techniques
Inventory Management in FMGIL
Categorization
Codification
Various procedure adopted for Inventory Management in FMGIL
SECTION C: RESEARCH METHODOLOGY
Research Objectives
Research Methodology
SECTION D: FINDINGS AND SUGGESTIONS
SECTION E: BIBLIOGRAPHY
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Nothing concrete can be achieved without optimum combination of inspection and perspiration. LikeAll other studies, this work is also result of the interaction of a number of minds who directly orIndirectly have contributed for completing this project. I owe a lot to many for the inspection partIt is very difficult to acknowledge so precious a dept as that of learning as that of learning as its theonly debt that is difficult to repay expect through gratitudeIt is great honor and privilege and pleasure to express deep since of gratitude to MS.KAVITACHOPRA (project guide) to placing complete faith and confidence in my ability to carry out this studand for providing me their inspiration, encouragement, help, valuable guidance, constructive criticismand constraint interest. They took personal interest in spite of their numerous commitment and busyschedule to help me complete my project .my project would not have seen the light of day withouttheir masterly guidance and overwhelming help.
It gives me tremendous pleasure in acknowledging the valuable assistance extended to me by variousPersonalities in successful completion of this project report.
I thanks all these for helping me in spite of their busy schedules.At last but not least, I extent my heartfelt gratitude to my family and friends help, cooperation, &constant encouragement for successful accomplishment of my project.
Pooja rani
CERTIFICATE
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The project included in the project outlined INVENTORY MANAGEMENT SYSTEM
of FEDERAL MOGUL GOETEZE INDIA. Submitted to DESH BHAGAINSTITUTE OF MANAGEMENT OF COMPUTER SCIENCE affiliated to PUNJATECHNICAL UNIVERSITY.JALANDHAR for degree in master o busineadministration by POOJA RANI has been carried out under my supervision
This project report is her original piece of work & has not beesubmitted for any other degree at this or any other institute to best of my knowledge
PROJECT GUIDEKAVITA CHOPRA
DESH BHAGAT INSTITUTE OF MGMT &COMPUTER SCIENCEGOBINDGARH
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Chapter 1
Introduction
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It is good to have goodwillIt is good to have enthusiasmBut it is essential to have knowledge
Pt. J.L.NehruThe above quoted lines by the great soul Pt.J.L.Nehru rightly tell us learning is a very necessary
Part in ones life of one wants to achieve success &have proper knowledge about a particular aspect.
Thus, the objective of my project report was to get more knowledge and to go beyond the bookish thgives
Merely theoretical knowledge and to closely look at the practicality of the modern industry.
The topic of my project is INVENTORY MANAGEMENT which was meant to know
The project was carried at. FEDERAL MOGHUL GOETZE (INDIA) LIMITED, Bahadurgarh,
Aspects of inventory management like
Inventory control system, material planning and purchasing, categorization of items, valuation of
Inventory etc.
The first section of the report is company profile, which includes the introduction of organization
Group, a brief overview of FEDERAL MOGHUL GOETZE INDIA LIMITED and finance aspects a
FMGIL.
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In the second section, an introduction to inventory management is given which includes
Inventory control system, material planning and purchasing, categorization of items,-Invento
management at FMGIL is been explained. The various aspects of inventory management lieconomic order quantity technique, ABC classification,
In the section-C and D, research findings are described which are used to gather the necessarinformation and suggestions regarding different aspects of inventory management are included..The last section of the report section-E includes Bibliography.
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Established in 1954, Goetz (India) Limited (GIL) is joint
Venture between the Anil Nanda group and Federal Mogul, a
Global supplier of quality products and solutions to automotive
Industry. Goetz (India) Limited was established in 1954
as a joint venture with Goetze-Werke of Germany.
Goetze-Werke of Germany is now owned by Federal-
Mogul Corporation, a $6.3 billion global company and
One of the leading manufacturers of automotive
Components in the world.
Federal-Mogul Goetz (India) Limited is the largest
Manufacturer of pistons and piston rings in India.
Federal-Mogul has been creating value through innovation and leading technology for
More than 100 years. Today, the company is a key player in the global marketplace,
Serving industries that range from automotive and commercial vehicles to railroad and
Aerospace. Customers know they can rely on Federal-Moguls quality excellence in
Products, trusted brands and creative solutions.
This company started with a bold idea and over time grew into a FORTUNE500
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Company with a global workforce thousands strong. The Federal-Mogul team has
Celebrated countless victories and worked hard to overcome the inevitable challenges.
The products basket besides pistons and piston rings also includes cylinder liners,
Light alloy castings and other sintered products. The company has its plants located at
Bangalore (pistons, piston rings and pins), Bhiwadi (sintered products) .The company
Has set up its first unit at Patiala (piston, rings, cylinder liners and castings). and
Started commercial production in 1957.
GIL has installed production capacity of 11 million pistons and 53 million piston
Rings.
ACQUISITION OF ESCORTS MAHLE LTD
Escorts Mahler Ltd. was a 50:50 joint venture between Escorts Ltd. & Mahle GmbH (Mahlmanufacturing Pistons & Piston Pins at Bangalore & Patiala. Pursuant to the disengagement
share purchase agreement among Escorts Ltd, Mahle & Escorts Mahle Ltd. Mahle h
decided to exit from the joint venture & sell its entire share holding in Escorts- Mahle Lt
Having decided to exit from this joint venture, also sold its entire share holding in Escort
Mahle Ltd.
In view of the fact that the businesses of the Escorts-Mahle and Goetz (India) Ltd., are close
inter-linked and have obvious financial and technical synergies due to common locations
plants, common customers, complementary products etc., it was considered advisable in th
interest of the company to acquire the share capital of the Escorts-Mahle Ltd. through t
special purpose vehicle (100% subsidiary). The new company named ESCORTS PISTON
LTD. came to existence on Nov.1, 2002.
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Further, Escorts Pistons Ltd. was amalgamated with Goetz (India) Ltd. on May 26, 2003 an
w.e.f. June 2003, the name of the company is GOETZE INDIA LTD.
Ab out Federal-Mogul
Federal-Mogul is a global supplier of automotive components, modules and systems serving th
world's original equipment manufacturers and the aftermarket industry. The company utilizes
engineering and materials expertise, proprietary technology, manufacturing skill, distributi
flexibility and marketing power to deliver quality products and services, and leading brands. Federa
Mogul is focused on driving global profitable growth and creating value to satisfy customer, employ
and stakeholder expectations.
Headquartered in Southfield, Michigan, the Company, which reported sales of $6.3 billion in 200
employs 42,000 people worldwide. Federal-Mogul was founded in Detroit in 1899. The Company
principal customers include many of the worlds foremost original equipment manufacturers
automotive, light commercial, heavy-duty truck, agricultural, marine, rail and industrial vehicles an
equipment as well as the worldwide aftermarket.
Federal-Moguls products are sold under a variety of power brands, including but not limited to, AE
engine products, ANCO wipers, Champion spark plugs and wipers, Fell-Pro gaskets, Ferodo
brake pads, Glycol bearings, Goetz piston rings, Moog chassis products, National wheel-e
components, Neural pistons, Pain gaskets, Sealed Power engine products and Wagner lighti
and brake products
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Product Range: Pistons, piston rings,cylinder liners,light alloycastings, sintered products
Quality Policy
Production Capacity: Piston rings 55 MillionPistons 13 Million
Turnover: April 09-March 10 INR 5124 Million
Net Profit (after tax): April 09 -March 10 INR (505) Million
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GOETZE (INDIA) LIMITED commits itself to leadership in national market for all i
products and ensuring total customers satisfaction highest in industry. It commits
develop and build an image in the international market to achieve a sustained annu
growth in exports.
Policy
We shall continue to manufacture all our products in conformity with accepte
international norms/ standards.
We shall also continue to retain our leadership in development of products throug
technical know-how from our Collaborators and in-house developments.
Consistent development of human resources through training at all levels will be ou
major thrust area.
ANIL NANDA
(Chairman & Managing Director)
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IMPORTANT PRODUCTS
Pistons
For their original equipment, FEDERAL MOGUL Pistons is the first choice of eve
discerning manufacturer like Telco, John Deere, Hindustan Motors, Mitsubishi Lancer, Ta
Cummins, Ashok Leyland, Mahindra, Escorts, Either, Maruti, Bajaj Auto, Fiat, Bajaj Temp
TVS, Yamaha motors, Swaraj Mazda etc.
GOETZE has state of the art test bed facilities, Design facilities for products, dies and toolin
with CAD PROE and test bed facilities.
Production Capacity: 10 million Pistons per annum
Production Range: 30 mm to 300 mm Dia
Application
Bi-Wheelers,
Cars,
Jeeps,
Tractors,
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Light Commercial Vehicles,
Heavy Commercial vehicles,
High out put locomotive diesel engines
Stationary Engine
Industrial
Products suitable for
4 Stroke Engines
2 Stroke Engines
Gasoline Engines
Diesel Engines
CNG Engines
Features
Autothermic
Autothermatic
Ring Carrier / Alfin
Double C.I. Grooves
Forged
Steel cap pistons
Pistons with cooling coil
Thin Walled Pistons for Cars
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Thin Groove pistons
GOETZE Piston Rings are the first preference ofOEMs & after market in
India. GOETZE has state of the art design facilities for products, tooling with CADPRO-
and test bed facilities.
Goetze is committed for Innovation, introduction of new technology and continuo
improvement in its products.
Production Capacity: 53 million Rings per annum
Range: 30mm to 300mm DIA
Goetze manufactures a wide range of piston rings for:
Bi-wheelers
Tractors
Passenger Cars & Jeeps
Commercial Vehicles (HCVs, MCVs & LCVs)
Locomotive Engines
Stationary Engines
Industrial Tx Type Expander & Cr Plated Rails
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Coating on Running Surface
Chrome Ceramic plated rings (CKS)
Molybdenum Coated Rings
Plasma Filled Rings
Semi-Inlaid Rings
Ferrox Filled Rings
Chrome Plated rings
Chrome Plated Ring
Salient Features
Thin rings made from SG Iron
Asymmetric profile rings
Specially honed chrome rings
Lower sharp edge rings
Reverse torsion rings
Conformable Chrome Oil Rings
Keystone
Napier
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Cylinder Liners
GOETZE manufactures wet and dry types of cylinder liners with honing, and sleeves for b
wheeler applications for our quality conscious customers.
Application
Bi-wheelers
Cars
Tractors
Light Commercial Vehicles
Heavy Commercial Vehicles
Stationary Engines
Range Production Capacity: 50 mm to 120 mm Internal Dia
Production Capacity: 0.5 million liners per annum
Features
Thin wailed
Plateau boned
With and without flanges
Coating
Phosphating
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Light Metal Casting
Goetze (India) Ltd. is making a wide variety of Light Metal Castings. These include CylindBlocks, Cylinder Heads, Aluminum tube castings and Aluminum crown handles for sing
cylinder engines.
Sintered Metals Products
Goetze India Limited (Sintered Products Division), produces a wide range of sintered met
products for varied automotive applications such as valve, trains, transmission and oil pump
with technical assistance from manufacturing facilities and R&D centers of Federal mog
sintered products in U.K., France and USA.
Goetze (India) Limited (Sintered Product Division) are suppliers to most of the O.EMs in Ind
and abroad. Some of these are:-
Maruti Udyog Limited
Tata Motors
Bajaj Auto Limited
Tvs
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Eicher Motors
Mahindra & Mahindra
Escorts
Swaraj Mazda Ashok Leyland
Hero Honda
Valve Train Parts
Valve seat inserts and valve guides are a special category of sintered components for ne
generation engines. Goetze India limited (Sintered Product Division) uses latest technology
processes along with specially sourced powder Little wonder that auto majors manufacturin
engines for varied applications such as two/three wheelers, passenger cars, LCV MCVs, HC
and tractors prefer GIL Sintered Products.
Synchronizer Hubs
Sintered Synchronizer Hubs offer a very cost effective alternative to conventional hubs and
the same time, meet the ever-increasing performance requirement of automotive designers.
Oil Pump Rotor & Gears
Sintered Oil pump rotor & gears are one of the widest used sintered application in a
automotive industries. Goetze India Limited (Sintered Products Division) with support fro
Federal Mogul Sintered Products R&D centers has developed its own capabilities to desig
and manufacture oil pump motors.
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HISTORY MILESTONES
1954 Incorporated as a JV with Goetze Werke
1957 Ring & liner production Patiala
1958 Piston production as escorts(Automotive Division)(Collaboration:Mahle)
Patiala
1960Cast iron / Forged piston productionstarted
Patiala
1968 Pins / ring carrier production started Patiala
1977 Piston / ring production started Bangalore
1982 Steel rings / Large bore locomotivepiston
Bangalore
1985 Light alloy products Patiala
1989 Auto thermic pistons production Bangalore
1990 Moly coated / IKA / chrome oil ringsPatiala
1992Large bore rings / pistons for battletanks
Bangalore
1994 Composite pistons / new ring foundryBangalore
1996 Escorts (Automotive Division) hived off into joint venture with M/S Mahle,Germany
1997 Goetze TP (India) Ltd. - Manufacturer of steel rings
2001 Merger ofFederal-Mogul sintered products Ltd. with Goetze (India) Ltd.
2003 Merger of Escorts pistons activities with Goetze (India) Ltd.
2004 Introduction ofchrome-ceramic rings
2004 Technical collaboration for pistons with Federal-Mogul Corporation
2006 Majority stakeholding acquisition by Federal-Mogul Corporation
2006 Name changed "Goetze (India) Limited" to "Federal-Mogul Goetze (India)
Limited"
MEMBERS OF
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MANAGEMENT BODY
Chairman (Non-Executive) Mr. Charles B. Grant
Vice Chairman, Managing Director& C.E.O.
Mr. Arun Anand
Director Mr. Rainer Jueckstock
Director Mr. Charles H. Polzin
Director Mr. Mukul GuptaDirector Mr. Vishvjeet Kanwarpal
Management
Managing Director and Chief Executive Officer Mr. Arun Anand
Corporate Leaders
Executive Director - Sales, Marketing & Applications Mr. Mohan Narayanan
a.Original Equip. Sales Mr. Yogesh Choudhary
b.Aftermarket & Sales Mr. Sanjeev Singhc.Exports Mr. G. S. Arshi
Executive Director - Manufacturing Operations Mr. Andreas Kolf
a.Bangalore Plant
ManagerMr. K. Saravanan
b.Patiala Plant Manager Mr. Sunit Kapur
c.Bhiwadi Plant
ManagerMr. A. R. Ahuja
Director - Finance & Secretariat Mr. Rajan Luthra
Director - Plant Finance Mr. Rustin Murdock
Director Projects Mr. Rakesh Anand
Director Procurements Mr. A. R. Ahuja
CHRONOLOGICAL VIEW OF PRODUCT INTRODUCTION AT
GOETZE.
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1954 Piston Rings and Cylinder Liners
1960 Pistons
1961 Assembly of Tractors
1962 Motorcycles, Railways Couplers
1963 Automatic Shock Absorbers
1965 Escorts Tractors
1969 Ford Tractors
1971 Industrial and Construction Equipments
1979 Excavator Loaders
1981 Yamaha RX-100, 100 CC Motorcycles
1985 Electronic PABX
1991 Harvester Combines
1992 VSAT Satellite Communication Systems
1993 Mobile Communications
2008 Forklift Trucks
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Company MARKET SHARE OF PISTON
MANUFACTURES IN INDIA
Company Name Market Share (%)
Goetze 36.5
Perfect Circle 12.0
IP Ring 16.5
Shriram Piston 22.5
SAMKRG Piston 9.0
Menon Piston 3.5
36.5
1216.5
22.5
9 3.5
Goetze
Perfect Circle
IP Rings
Shriram Piston
SAMKRG Piston
Menon Piston
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EXPORT DESTINATION
Dubai
Bangladesh
Singapore
Egypt
Mauritius
U.S.A
Germany
Nepal
Sri Lanka
COLLABORATIONS
A. GERMANY
Faun
Class
B. JAPAN
Yamaha
Kayaka
Mikni
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C. UK
JCB (Goetze)
Ford
D. USA
HUGHES
E. FRANCE
Bosch
Dynapal
SIGNIFICANCE OF LOGO
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The logo of Federal Mogul Goetz (India) Limited has been prepared with certa
objective in mind and is symbolic in more than one way.
So, overall, the logo represents GILs concern for Workmanship, Quality and Technology.
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Vision of the company
To be one of the worldss leading automotive solutionsprovider
Mission of the Company
Our company has committed to increase shareholder value by aggressively pursuing grow
and profit opportunities by providing irmovative diverse and high performance products an
solutions to meet our customers needs. We shall provide our work force with an environme
that develops teamwork, continuous learning and Improvements that rewards good performer
We wall support our products with 11 technical expertises at the customers end. W. Value th
Environment and the community and would lice to build better ftiture for our children..For o
company customer are king and our aim is to satisfy the need of the customers. In short
Steadily moving towards leadership with piston with vision strategy seein
it as the best way to leaders in business
Certifications Achieved
The Patiala and Bangalore Plant are both ISO 9001 I QS 9000 certified and under ISO I T
16949 and ISO 14001 certification. Bhiwadi Plant is also having the certification of ISO / T
16949/ISO 14000 certified.
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IMPORTANT CUSTOMERS
Ashok Leyland Ltd.
BajajAutoLtd
Bajaj Tempo Ltd
Birla Yamaha Ltd.
Eicher Motors Ltd.
Elgi Equipments Ltd.
Escorts Ltd. (Auto Suspension Division)
Escorts Ltd. (Farmtrac Division)
Escorts Ltd. (Tractor Division)
Frick India Ltd.
Hero Honda Ltd.
Hero Motorcycles & Scooter Ltd.
Hero Motors Ltd.
Hindustan Motors Ltd.
Honda Seil Power Products Ltd.
Indian Railways
International Tractors Ltd.
Kinetic Engg. Ltd.
Kinetic Motors India Ltd.
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Kirloskar Oil Engines Ltd.
JAPANESE PRACTICE OF 5-S
Goetze has adopted the Japanese Practice of 5s.
This enables the plant to have better working conditions and also increase work efficiency.
copy of it also displayed at each shop and depth to motivate the employee towards health
work environment.
Meaning and benefits of 5S system are as follows
1. SEIRI: It stands for Sorting
Take out necessary items and suitably dispose with them
Benefits:
1. Effective Space Utilization
2. Stop Material from deteroiting or getting damaged
3. Reduce wastage and searching items
2. SEITON: It stands for Set in Order
Arrange. all necessary items in a proper order so that they can be easily picked up for use
Benefits:
1. Reduce preparation and machine setting and machine setting timings.
2. Reduce time in locating or waiting for Tool Parts and Machines.
3.SIIESO: It stands for Shine/Completely Clean
Clean your workplace completely so that there is no dust anywhere.
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Benefits:
1. Promotes Orderly and Safe Working Environment
2. Reduces Breakdown and Accidents.
3. SEIKETSU: It stands for Standardize
Maintain a high standard of house keeping and work place organizational at all times
Benefits:
1. Quick Response through Visual Management
2. Create a maintenance system of House keeping for all the times.
4. SHITSUKE: It stands for Self Discipline Attitude
Train People to follow Good House Keeping Discipline Independently
Benefits:
1. Self Di scipline
2. Improves Industrial Safety
3. Creates Healthy Attitude and Habits
Advantages of 5S
Healthy Working Environment
Improves Work Efficiency
Producting Better Quality Products and Higher Productivity
Cutting Cost Down
Ensuring Delivery on time
Safe Working
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High Morale and Better Life
ORGANISATION SET UP
The organizational set up of the following departments is studied in detail:
1. Finance Department
2. Personnel Department
3. Purchase and Store Department4. Production Department
FINANCE DEPARTMENT
D.G.M. (Finance), Patiala who is directly responsible to Plant Head (Finance and Accounts), one
the most reputed Functional Department in GOETZE (INDIA) LTD. C.G.M. manage the Departme
and under him there are two managers, one is Finance Manager and other is Costing Manager. Th
Finance Manager is assisted by two supervisors one of these is responsible for cash and bank balanc
and other is responsible for bills payable. Each supervisor is given two or three assistants to wo
under him.
The amount of investment to be put in current assets like cash in hand, bank balance, loans an
advances, inventories, accrued expenses, dividends payable etc. all are decided by Finan
Department.
The realization of cash for the purpose of raw materials components and spares to pay wages an
salaries to incur day to day expenses and overhead costs, to meet selling costs to provide cred
facilities to customers and to maintain inventories is also the function of this department.
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Inventory managementThe formulation of policies with regard to profitability risk and liquidity, decisions about comparis
and level of current assets and liabilities, formulation of production policy to keep the production
steady by accumulating inventories, formulation and execution of credit policy is also the function
Finance Department.
This Department is responsible for handling transaction relating to purchase of raw material as well
accounts relating to sales. It is also concerned with payment of all expenses incurred by the compan
like purchase of raw material, electricity bills, repairs etc. It is also concerned with valuation
various costs relating to inventories.
It deals with determination of monthly wages, salaries of employees, fringe benefits of retiremen
provident funds deduction, incentives, bonus and all the rewards, which the employees get f
rendering their services to the company
Functions of Finance Department
Cash Flow:
The plant is preparing C.F. statements, to be conveyed to HO. These include sources as well
application of funds. Similarly applications of funds related to the salary, payment to suppliers. Maj
expenses (like Electricity, Telephone Bills, Excise duty and other personal & sales & administratio
expenses).
Costing:
The costing is being done for all the products manufactured at the plant. These relate to Piston, Rin
Cylinder Liners and Light Alloy Products. The Historical base is being followed for costing purposes
Consumption:
Every item being received in the plant for consumption. Input is being accounted for at the plant. Th
ledgers are maintained for every receipt and issue.
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ORGANIZATIONAL CHART OF FINANCE DEPARTMENT
Mr. Ajay Singla(Manager Finance)
Costing, Fixedassets & CWIP
GeneralAccounting
MIS Reporting Store A/cing &Bills Payable
Mr. S P SinghChopra
Mr. Inderjit Singh
Mr. ManmohanSingh
Mr. BharatBhushan
Mr. Sarbjit Singh
Mr. O P Ghai
Mr. Ranjit Singh
Mr. RabinderSingh
Mr. HarinathSingh
Mr. RameshKumar
Mr. AshokKumar
Mr. RavinderKumar
Mr. SureshKumar
Mr. RajneshUppal
Mr. Ajay Jind
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PERSONNEL DEPARTMENT
Personnel department advises the management on all matters relating to personnel administration. Th
top management takes into account its advice before arriving at final decisions on personnel an
administrative matters. Personnel Policies in GOETZE (INDIA) LIMITED have been divided in
three parts:
a. PERSONNEL FUNCTIONS to encourage the adoption and utilization of lat
methods and techniques in areas of manpower planning and development and keeping avenu
of promotion open to employees.
b. PROVISION OF COMMUNICATION, TRAINING AND WELFAR
MEASURES, EMPLOYEE COMMUNICATION so that employees contributes their best companys objectives and also get opportunities for advancement and self-development.
c. INDUSTRIAL RELATIONS between employer and employee so as to promo
satisfactory relations by providing channels for upward and downward communication an
establishing systematicprocedure for redress.
PURHCASE AND STORE DEPARTMENT
Purchase and Store are two Departments, which go hand in hand. It is very essential that there shou
be proper synchronization between Purchase Department and Store Department.
In GOETZE (INDIA) LIMITED, the main responsibility of Purchase Department is to receive orde
from other Departments, do the market survey, list the potential sellers and the rates, choose the be
and go ahead with purchase. The purchase order is placed only with approved contractors. Th
Purchase Department scrutinize the following aspects:
a) Quality and Technical specifications
b) Delivery
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Inventory managementc) Prices
Once the purchase order has been placed, it is sent to stores where the store gets ready to receive t
incoming material. When the material is received, a notification is sent to the Finance Department.
Stores deal with an array of material, which can be divided into:
a) Raw materials
b) Components
c) Standard items or patent items
d) Miscellaneous items
PRODUCTION DEPARTMENT
The Department is responsible for production of various items fixed on basis of production budgewhich includes:
a) Raw material budget
b) Labor budget
c) Plant utilization budget
GOETZE (INDIA) LIMITED turns out a wide variety of Piston Rings for Bi-Wheelers, Heavy Lig
Commercial Vehicles and Motor Cars etc. The Company has maintained steady growth in Pisto
Rings in view of ready acceptability of its products. Form modes production of 22517 rings in 1957
touched a figure of 28 million in 2009-10
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Inventory management
INTRODUCTION TO INVENTORYMANAGEMENT
Inventory management refers to the process of managing the stocks of finished products,
Semi-finished products and raw materials by a firm. Inventory management, if done
Properly, can bring down costs and increase the revenue of a firm. How much one should
Invest in inventory management? The answer to this question depends on the volume and
Value of inventory as a percentage of the total assets of a firm.
Inventory Management involves the control of assets being produced for the
purposes of sale in the normal course of the company's operations. The goal of
effective inventory management is to minimize the total costs - direct and
indirect - that are associated with holding inventories. However, the importance
of inventory management to the company depends upon the extent of investment in
inventory.
The task of inventory planning can be highly complex in manufacturing environments. At the
same time, it rests on fundamental principles. The system used for inventory must tie into the
operations of the firm. Inventory planning and management must be responsive to the needs
of the firm. The firm should design systems, including reports that allow it to make proper
business decisions
The.
Inventory Management system and the Inventory Control Process provides informatioto
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Inventory management
Efficiently manage the flow of materials; effectively utilize people and equipmencoordinate
internal activities, and communicate with customers. Inventory Management and thactivities of
Inventory Control do not make decisions or manage operations; they provide thinformation to
Managers who make more accurate and timely decisions to manage their operations.
The basic building blocks for the Inventory Management system and Inventory Contractivities ar
Sales Forecasting or Demand Management
Sales and Operations Planning
Production Planning
Material Requirements Planning
Inventory Reduction
TYPES OF INVENTORY
Four kinds of inventories may be identified:
1. Raw materials Inventory: This consists of basic materials that have not yet been
Committed to production in a manufacturing firm. Raw materials that are purchased from
firms to be used in the firm's production operations range from iron ore awaiting processing
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Inventory managementinto steel to electronic components to be incorporated into stereo amplifiers. The purpose of
maintaining raw material inventory is to uncouple the production function from the purchasing
function so that delays in shipment of raw materials do not cause production delays.
2. Stores and Spares: This category includes those products, which are accessories to the
main products produced for the purpose of sale. Examples of stores and spares items are
bolts, nuts, clamps, screws etc. These spare parts are usually bought from outside or some
times they are manufactured in the company also.
3. Work-in-Process Inventory: This category includes those materials that have been
committed to the production process but have not been completed. The more complex and
lengthy the production process, the larger will be the investment in work-in-process inventory.
Its purpose is to uncouple the various operations in the production process so that machine
failures and work stoppages in one operation will not affect the other operations.
4. Finished Goods Inventory: These are completed products awaiting sale. The purpose of
finished goods inventory is to uncouple the productions and sales functions so that it no
longer is necessary to produce the goods before a sale can occur.
Methods adopted to value raw material inventory control
The following methods can be adopted to value the raw material:
First-In-First-Out (FIFO): When a firm adopts the FIFO method to price its raw material, the
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Inventory managementissue of material from the stores will be in the order which it was received. Thus the pricing
will be based on the cost of material that was obtained first.
Last-In-First-Out (LIFO): In the LIFO method, the material issued will be priced based on
the material that has been purchased recently.
Weighted Average Cost Method: The pricing of materials will be alone on weighted average
basis (weights will be given based on the quantity).
Standard Price Method: Material is priced based on a standard cost, which is
predetermined. When the material is purchased the stock account will be debited with the
standard price. The difference between the purchase price and the standard price will be
carried into a variance account.
Replacement / Current Price Method: In this method material is priced at the value that is
realizable at the time of the issue.
INVENTORY MANAGEMENT TECHNIQUES
While the total ordering costs can be decreased by increasing the size of order, the carrying
costs increase with the increase in order size indicating the need for a proper balancing of
these two types of costs behaving in opposite directions with changes in order size.
Again, if a company wants to avert stock-out costs it may have to maintain larger inventories
of materials and finished goods, which will result in higher carrying costs. Here also proper
balancing of the costs becomes important.
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Inventory managementThus, the importance of effective inventory management is directly related to the size of the
investment in inventory. To manage its inventories effectively, a firm should use a systems
approach to inventory management. A systems approach considers in a single model all the
factors that affect the inventory.
A system for effective inventory management involves three subsystems namely:
1.economic order quantity
2. reorder point
3. stock level
ECONOMIC ORDER QUANTITY
The economic order quantity (EOQ) refers to the optimal order size that will result in the
lowest total of order and carrying costs for an item of inventory given its expected usage,
carrying costs and ordering cost. By calculating an economic order quantity, the firm attempts
to determine the order size that will minimize the total inventory costs.
Total inventory cost = Ordering cost + Carrying cost
Total ordering costs = Number of orders x Cost per order
= $ U / Q X F
Where
http://www.azinventorymanagement.com/economic-order-quantity.htmhttp://www.azinventorymanagement.com/reorder-point.htmhttp://www.azinventorymanagement.com/stock-level-system.htmhttp://www.azinventorymanagement.com/economic-order-quantity.htmhttp://www.azinventorymanagement.com/reorder-point.htmhttp://www.azinventorymanagement.com/stock-level-system.htm -
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Inventory managementU = Annual usageQ = Quantity orderedF = Fixed cost per orderThe total carrying costs = Average level of inventory x Price per unit x Carrying cost
REORDER POINT FORMULA
One can adopt a much simpler formula which gives reasonably reliable results in calculating
at what point in the level of inventory a reorder has to be placed for replenishment of stock.
The formula along with its application is given below, using the notation developed earlier.
Reorder point = S x L + F ( S x Rx L)
Where
S = Usage in unitsL = Lead time in daysR = Average number of units per orderF = Stock out acceptance factor
The stock-out acceptance factor, `F', depends on the stock-out percentage rate specified and
the probability distribution of usage (which is assumed to follow a Poisson distribution). For
any specified acceptable stockout percentage the value of `F' can be obtained from the figure
presented below.
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Inventory managementSTOCK-LEVEL SUBSYSTEM
This stock level subsystem keeps track of the goods held by the firm, the issuance of goods,
and the arrival of orders. It maintains records of the current level of inventory. For any period
of time, the current level is calculated by taking the beginning inventory, adding the inventory
received, and subtracting the cost of goods sold. Whenever this subsystem reports that an
item is at or below the reorder-point level, the firm will begin to place an order for the item
SAFETY STOCK
Once again in real life situations one rarely comes across lead times and usage rates that
are known with certainty. When usage rate and/or lead time vary, then the reorder level
should naturally be at a level high enough to cater to the production needs during the
procurement period and also to provide some measure of safety for at least partially
neutralizing the degree of uncertainty.
The question will naturally arise as to the magnitude of safety stock. There is no specific
answer to this question.
However, it depends, inter alia, upon the degree of uncertainty surrounding the usage rate
and lead-time. It is possible to a certain extent to quantify the values that usage rate and
lead-time can take along with the corresponding chances of occurrence, known as
probabilities. These probabilities can be ascertained based on previous experiences and/or
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Inventory managementthe judgmental ability of astute executives. Based on the above values and estimates of
stock-out costs and carrying costs of inventory it is possible to work out the total cost
associated with different levels of safety stock.
Kanban
Another highly effective way of cutting down on WIP is through the use of kanban, Japanese for sign
Kanban is a tagging system that is essentially a communication system designed to inform production
across the entire plant about what to do and when to do it. Essentially this is a system that tells peopl
when to produce what
ABC Procedure for Categorizing of Inventory
The general procedure for categorization of items into `A', `B' and `C' groups is briefly
outlined below:
All the items of inventory are to be ranked in the descending order of their annual usage
value.
The cumulative totals of annual usage values of these items along with their percentages to
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Inventory managementthe total annual usage value are to be noted alongside.
The cumulative percentage of items to the total number of items is also to be recorded in
another column.
An approximate categorization of items into A, B, and C groups can be made by comparing
the cumulative percentage of items with the cumulative percentage of the corresponding
usage values.
Advantages of the ABC Inventory System
The advantages of the ABC system are as follows:
1. It ensures closer control on costly items in which a large amount of capital has been
invested.
2. It helps in developing a scientific method of controlling inventories, Clerical costs are
reduced and stock is maintained at optimum level.
3. It helps in achieving the main objective of inventory control at minimum cost.
4.The stock turnover rate can be maintained at comparatively higher level through .
scientific control of inventories.
The system of ABC analysis suffers from a serious limitation. The system analyses the items
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Inventory managementaccording to their value and not according to their importance in the production process. It
may, therefore, sometimes create difficult problems. For example, an item of inventory may
not be very costly and hence it may have been put in category C. However, the item may be
very important to the production process because of its scarcity. Such an item as a matter of
fact requires the utmost attention of the management though it is not advisable to do so as
per the system of ABC analysis. Hence, the system of ABC analysis should not be followed
blindly.
INVENTORY MANAGEMENT IN FEDERAL MOGUL GOETZE INDIA LTD
ABC Analysis is being used to manage the inventories. A category items contain high value items an
important material directly linked with production. It includes one product i.e. CIMSTAR MB62C.
Category includes items, which are directly linked with production but are having less value th
items. It includes three products i.e. SERVO SYSTEM 68% HYPSIN EP-68, Cutting oil, Arc ligh
Category C includes items products such as mobile oil, kerosene oil, power oil, servo system 12
servo CUS, quenching oil, preventing oil etc.
In stores computers are being used to store maximum, minimum, re-order levels of each item
Recently the firm has started using JIT technique.
The purchases of FMGIL are centralized and authority lies with the purchase departmen
Major purchase is done by head office but local purchase is also for certain items.
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Inventory managementProcedure of acquiring inventories starts with the receipt of material. When the mater
reaches the main gate it needs to be inspected and only after inspection of invoices materials is sent
the store department. Then the material is inspected and is approved or rejected as the case may be.
MATERIAL PLANNING AND PURCHASING
Purchasing in FMGIL is centralized and authority lies with purchase department. No body
allowed to make purchase himself, directly. For purchasing purpose a meeting is held at held office
which planning is done on basis of last years consumption. After the raw material planning has bee
made, purchase is done by the head office itself and planning report is sent to sub-offices. Althoug
major purchase is done by head office but local purchase can also be done for certain items.
The items, which can be locally purchased, are divided into two types:-
For local purchase as well as for head office purchase levels have been fixed as:-
RECEIPT OF MATERIAL
As the material reaches the main gate of the factory, security person puts stamp on backside
invoice or challan. After this the material reaches the Store department
INSPECTION OF MATERIAL
TYPE 4 TYE 5
(Locally purchasable) (Head office purchase stock items)
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Inventory managementOnce the material has been received by store then it is the duty of either inspection departme
or store department to inspect the material. Here it is checked out that the material is according
specification and the material quantity is neither greater nor lesser in number then the order placed if
is according to specification, then GIR is accepted.
According to the type of material, either physical verification is done or composition
material received is checked out. In physical verification, the quantity of material, the working order
material and specification fulfillment is taken into account e.g. for electronic goods. For checkin
composition of the material e.g. in case of alloy or sand it is seen out, whether the received materi
has proper composition as per requirements of the company.
ISSUE OF MATERIAL
In FMGIL the material is issued for two purposes:-
1. Direct purpose : for manufacturing of components
2. Indirect : generally in the nature of store and spares, tools etc.
Store department has two types of items:-
1. Stock
2. Non-stock
The material asked by various departments can either be stock items or non-stock items. If
department has to ask for stock items it prepares material indents form of the items required in whic
description of material is thoroughly provided. Four copies of indents are prepared Blue, Re
Yellow and White. The department keeps white copy, itself for record and other three copies are se
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Inventory managementto store department here, Red copy is kept by store for record purposes. Blue copy is sent to Finan
Department for evaluation while Yellow copy is sent to Purchase department.
If the material is being purchased for first time, then purchase department, asks for quotatio
from the supplier. According to these quotations, the purchase department Purchase the material. If
is routine material, then the material can be purchased from routine supplier without quotations. Stoc
items required by various departments from the store are issued as such and no yellow copy is sent
purchase department but both red and yellow copy are kept by store department itself. While blue cop
is definitely sent to finance department for evaluation of stock item.
CLASSIFICATIONS OF INVENTORY
FMGIL inventory can be classified under following three main categories:-
1. Raw material
2. Work in progress
3. Finished goods
The raw material inventory can be further classified and maintained under following tw
headings:-
1. Stores and spares
2. Tools, jigs and dies
CATEGORISATION OF ITEMS
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Inventory managementIn FMGIL categorization of items is done according to the following categories:-
1. ABC CLASSIFICATION
Under this system items are classified according to their value and usage rate. An item consis
of items having maximum value but minimum consumption. B items consist of items of modera
value and moderate consumption. C item consists of items having minimum value and maximu
consumption.
ITEM NO. OF ITEMS IN % AGE APPROXIMATE VALUE
A 10% 70%
B 20% 20%
C 70% 10%
2. XYZ CLASSIFICATION
This classification is based on the value of inventory at the end of a given period of tim
normally closing date of a financial year. X items are those whose inventory value is high, Y items a
those whose inventory value is medium and Z items are those whose inventory value is low
minimum.
3. SDE CLASSIFICATION (Scarce, Difficult and Easy Classification)
This classification is based on the problems that a company may face while purchasing of th
material from the market due to short supply or unavailability. Scarce items are those, which are
short supply in the market and are not easily available. Difficult items may be termed as those, whi
are not scarce but are difficult to arrange and delivery period is long. Easy items are normal standa
items stored by vendors and are routinely supplied as per orders.
4. GOLF CLASSIFICATION (Govt., Open, Local, Foreign Classification)
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Inventory managementThis classification is based on the source from which the suppliers are to be availed. Some
the items may be government controlled or available through government-canalized agencies. Som
items are easily available at central and local level and some items may be imported from oth
countries.
5. FSN CLASSIFICATION
This classification is based on the pattern of movement of items i.e. issue from stores. Fa
moving, slow moving and non-moving items. Fast moving items are regular items and are to be ke
mostly for regular supply.
CODIFICATION OF ITEMS
In FMGIL there are many items of inventory, due to such large number, codes have be
assigned to every item. However code assigned to every item follows a specification order, so th
easy identification of every item can be done. Emphasis on codification is considered very mu
essential in FMGIL.
51. RAW MATERIAL
52. FOUNDARY FLUXES, OILS AND LUBRICANTS
53. PACKING MATERIALS
54. GRINDING/ABRASIVE MATERIALS
55. DRILL
56. CUTTER
57. CARBIDE TOOLS58. MSSS/BRASS/PHOSPHOROUS MATERIALS
60. BEARING
61. V-BLT
62. CIVIL AND PIPE FITTING MATERIAL
63. RUBBER AND AEHED PRODUCTS
64. NUTS, BOLTS, WASHERS & SPACERS
65. HAND/INSPECTION TOOLS
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Inventory management
66. WELDING AND FIRE FIGHTING MATERIAL
67. WELFARE ITEMS
68. CASTINGS AND FABRICATORS
VARIOUS PROCEDURES ADOPTED FOR INVENTOR
MANAGEMENT IN FMGIL
PROCEDURE FOR CONTINUOUS IMPROVEMENT
Objective:-
To define procedure for continuous improvement.
Scope:- Stores
Responsibility
Head Stores
Supervisor Stores
Procedure:-
1) Continuous improvement is adopted across the board in stories.
2) Suitable areas of continuous improvement and techniques shall be identified by He
Stores and listed down in continuous Improvement Plan. Head stores shall prioritize projec
and appropriate actions shall be initiated.
3) Improvement/development observed in one area is suitably adopted in other areas.
4) Improvement activities shall be managed by using following steps:-
i. Deciding objectives for improvement.
ii. Team information.
iii. Action identification.
iv. System implementation, verification, documentation and training.
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Inventory management5) The progress on continuous improvement projects shall be reviewed duri
Management Review Meeting. The continuous improvement plan shall be reviewed a
updated, if necessary.
6) Results of various functional continuous improvement activities shall be communicat
and displayed in respective areas.
References:-
Continuous Improvement Plan
Management Review Report
PROCEDURE FOR INTRA-DEPARTMENT TRANSFER
Objective:-
To define the procedure for intra-plant transfer.
Scope:-
Items as per initial material list for purchase Patiala Plant and initial materialist for Head Offi
materials.
Responsibility:-
Chief Head Office materials
Head Incoming material
Head Laboratory
Head Stores
Head Purchase-Patiala Plant
Head User Department
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Inventory management
1. To know the functioning of the inventories and understand the system of procurement of
material , its receipt , inspection and its issuing.
2 . To understand the accounting and valuation of raw material , work-in-
progress and finished goods.
3 . To analyze the inventory control techniques used by company and
their techniques .
4 . To study the performance of the company in relation to inventories
and thus provide suggestions if any on the basis of analysis and
interpretataion of the data .
B : Research Methodology
The methodology used for the collection of data is of secondary type which is being explained here
SECONDARY DATA
It is mainly based upon annual reports , magazines , office reports and various published documents
FEDERAL MOGUL GOETZE INDIA LTD patiala.
Data has been collected for five years (i.e. financial year 2005-2010) , then compiled and thereafter
statistical analysis of the information has been done, thereafter various ratios relating to the inventori
has been calculated and tables showing variation in the inventories for five years have been made.
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Inventory management
SWOT ANALYSIS
Previous years were challenging with the companys business constrained by unfavorable econom
conditions. The slow down in the industrial production, in particular in the automobile industry, had a
adverse impact on the companys business.
S - STRENGTHS
W - WEAKNESSES
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Inventory managementO - OPPORTUNITIES
T - THREATS
1. STRENGTHS
The major strength of the company is that it is well established. The relationship betwe
management and employees is very good, as in agreement between management and employees w
signed on March 2010. Due to this agreement there is no fear of strikes and lockouts in the company.
Few competitors
Profit making and reputed firm
Availability of skilled and cheap labour
Technical efficiency
Operating efficiency
2. WEAKNESSES
The major weakness of the plant is that it does not have Marketing Department and it has
depend totally on Head Officer for marketing activities.
Low return of capital employed.
Problem of timely availability of raw material.
Facing some infrastructure problems.
3. OPPORTUNITIES
With the implementation of EURO norms, there is need for high strength material rings whe
realizations are much better as compared to standard rings. In this high technology value segment t
unorganized sector cannot compete and thus there is tremendous opportunity for the company
increase domestic competition. There are increasing opportunities for exports to.
High export opportunity.
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Inventory management
Scope for further expansion in production of existing products and some new products h
increased.
4. THREATS
The company faces normal market competitions form other manufacturers and the unorganiz
sector especially for the low value segment of industrial and bi-wheeler 2 stroke rings.
With the ongoing liberation of imports and deregulation of Indian economy, there is a maj
threat from cheaper imports, particularly from China.
FINDINGS
After carrying out in depth study of the system and procedure of inventory management bein
followed at FMGIL.
It has been found that in spite of high inventory levels so much care is taken off. There h
been a tremendous increase in the inventory levels.
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Inventory managementNo consideration is given to maintain maximum and minimum levels of inventory. Econom
Order Quantity (EOQ) system is not followed properly in Escorts. Among ABC class items no speci
care has been take of B and C class items although in absolute value the amount to crores
investments. Crores of investment is becoming slow moving every year, which is turn is becomin
non-moving whose investment is already very high.
But a good thing is found in the form of MIS reports prepared on regular basis by Finan
Department to manage inventory level and review of slow and non moving items by all concern
agencies on annual basis.
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Inventory management
Standardization of tools can help to eliminate reluctant inventories through reduction
inventory levels, which are increasing due to frequent changes in models of pistons etc.
Problems of past should be kept under consideration and inventory holding norms of we
established items should be thoroughly received, while fixing the new inventory norms.
Theoretically maintained levels should also be followed practically to stop inventory crossin
This will make reduction in inventory levels possible.
The company needs to improve its inventory turnover ratio ensuring change of inventories
sell at faster rate.
The company should try to increase its production by bringing in new technology and reducin
its cost.
The concern should try to pay more attention on raw material conversion period because b
this they can reduce the duration of manufacturing cycle for this they should try to reduce the ra
material inventory and also by increasing production.
In store and spares a part of inventory, there are certain items, which are slow moving, an
there are also certain items which are non moving. The firm should reduce the investment in the
items as the funds blocks in these can be efficiently utilized.
MRIR preparations may be restricted to 8 to 15 days. So that adverse insurance coverage an
over stocking implications could be avoided.
Earlier company was using wood boxes for packing finished goods, which were quite safe, an
a proper transportation. But now the company is using cardboard boxes for packing yet company h
reduced the weight of packing material per box. But quantity of rejected finished material in invento
has increased. So company should give attention to improve packing material to maintain
reputation and reducing cost of inventory.
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Inventory management
BIBLIOGRAPHY
INTERNET WEBSITES:
Foundational work
http://www.inventory management.com/inventory_management_blog.html
http://www.inventorymanagementreview.org/2005/10/different_inventory.html
http://www.inventorymanagement.com/labels/inventorymanagement.html
Comprehensive overview
http://www.sageMAS_90_200_inventory_spec.pdf/22586.pdf
http://www.sba.gov/library/pubs/mp_22pdf
http://www.SKUflow.com/refferals.asp
http://www.inventorymanagement.review.org/2005/10/cutting _down_on.html
http://www.azinventory management.com/working_capital.html http://www.azinventorymanagement.com/planning.html
http://www.azinventorymanagement.com/business_pages.html
http://www.answers.com/stock keeping units/reference.jsp
Theories
Donald W.Dobler, David N. Burt, (2005), purchasing and MaterialsManagement,Inventory Management, pp -Z440-460.
http://www.inventorymanagementreview.org/2005/10/different_inventory.htmlhttp://www.inventorymanagementreview.org/2005/10/different_inventory.htmlhttp://www.inventorymanagement.com/labels/inventorymanagement.htmlhttp://www.inventorymanagement.com/labels/inventorymanagement.htmlhttp://www.sba.gov/library/pubs/mp_22pdfhttp://www.sba.gov/library/pubs/mp_22pdfhttp://www.skuflow.com/refferals.asphttp://www.skuflow.com/refferals.asphttp://www.inventorymanagement.review.org/2005/10/cutting%20_down_on.htmlhttp://www.inventorymanagement.review.org/2005/10/cutting%20_down_on.htmlhttp://www.azinventorymanagement.com/planning.htmlhttp://www.azinventorymanagement.com/planning.htmlhttp://www.azinventorymanagement.com/business_pages.htmlhttp://www.azinventorymanagement.com/business_pages.htmlhttp://www.answers.com/stock%20keeping%20units/reference.jsphttp://www.answers.com/stock%20keeping%20units/reference.jsphttp://www.inventorymanagementreview.org/2005/10/different_inventory.htmlhttp://www.inventorymanagement.com/labels/inventorymanagement.htmlhttp://www.sba.gov/library/pubs/mp_22pdfhttp://www.skuflow.com/refferals.asphttp://www.inventorymanagement.review.org/2005/10/cutting%20_down_on.htmlhttp://www.azinventorymanagement.com/planning.htmlhttp://www.azinventorymanagement.com/business_pages.htmlhttp://www.answers.com/stock%20keeping%20units/reference.jsp -
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Inventory management
Jain S.P, Narang K.L, (2001), materials control, Cost Accounting, Kalyani Publishers,Edition.16.
Questionnaire filling by organization employees to know about inventory management
NameAgeDesignationDepartment
1-which techniques used by your organization to control the inventory?
2-which methods are used by your organization for inventory management?
3 who prepared the MIS report of inventory in your organization and which basis it prepared?
4-inventory turnover ration of your organization?
5-level of inventory you kept your organization?
6-which categories the inventory of your organization classified?
7 Is your organization adopt EOQ model for inventory management or control?
8 how your organization maintain the level of inventory?
9-conversion period of inventory?
10-which is most appropriate method used by your organization for manage the inventory
Thank you
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Inventory management