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UNIVERSITY SYLLABUS
Inventory Control: Inventory, cost, Deterministic models, Introduction to supply
chain management.
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INVENTORY CONTROL
Inventory is the materials in stock or the idle resource of all enterprise. They are either stocked
for sales or they are in the form of materials which are yet to be utilized.
TYPES OF INVENTORIES- A manufacturing plant has following types of inventories:
Inventory
Direct Inventory
Indirect Inventory
Raw
Bought Work-in Finished Maintenance,
Tools
Miscellaneous
materials out parts process
goods
Repair and
inventory inventories:
Operating Stores
Direct Inventory: Direct inventory is that inventory which becomes the part of the final product.
e.g. Pipes, Channels in a fabricated item; cloth thread and buttons etc. in a readymade garment.
Indirect Inventory: Indirect inventory is that inventory which does not become a part of the
final product. e.g. Stationery items, oil and lubricant for the machine etc.
(i) Raw materials: are those which have not undergone any operation since they are received
from the suppliers such as pipes, channels etc.
(ii) Bought out parts: are finished parts, subassemblies purchased from outside as per the
companys specifications.
(iii) Work-in-process inventories (WIP): are semi-finished products at the various stages of
manufacture.
(iv) Finished goods inventories: are the completed products ready for dispatch.
(v) Maintenance, Repair and Operating Stores: are consumed in the production process, such
as oil, grease etc.
(vi) Tools inventory: such as standard tools and special tools.
(vii) Miscellaneous inventories: are office stationeries and other consumable stores.
Need of Inventories
Inventories are needed to:
1. Ensure in-time deliveries and better customer relations.
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Re order Level
Safety Stock
Lead Time
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Lead Time
This is also known as procurement time. This is the total time taken from the time stores sends
its purchase requisition to the purchase department, to the time the material is taken into stock in
the stores. Lead time includes the time taken for the following activities.
1. Sending the purchase requisition by stores department.
2. Calling for quotation and approval.
3. Placing the purchase order.
4. Delivery time taken by the supplier.
5. Transportation of material.
6. Receiving material at the company.
7. Inspection of material received.
8. Entering the material into stock.
Reorder Level
This is the level of stock in stores at which a purchase requisition is placed to procure material.
The reorder level is minimum stock plus the lead time requirement. When this level is reached,
the store keeper sends a purchase requisition to the purchase department. In figure the reorder
level is C.
INVENTORY MODELS
1. Static Inventory Models: It is applicable where only one order can be placed, due to
perishable or seasonal nature of items (Coolers, Fridge, Umbrellas).
2. Dynamic Inventory Model: In this repeat order can be placed Further classified into
two:a) Deterministic Model: These models are based on the assumption that the demand as well as
lead time are deterministic.
b) Probabilistic Models: These models take into account the variation in demand and lead time
of an item.
INVENTORY COSTS
The inventory control models are based on different types of inventory costs. These costs can be
grouped as follows:
(1) Purchase cost: is unit purchasing cost for availing the price discount and is expressed in Rs.
Per unit.
(2) Capital cost: is the amount of capital not available for other purchases.
(3) Ordering cost: This cost includes the expenses on the following functions:
(i) Calling quotations.
(ii) Processing quotations.
(iii) Placing purchase orders.
(iv) Receiving and inspection of materials.
(v) Verifying and payment of bills.
vi) Order incidental charges, etc.
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Ordered Quantity
Shortage Cost: It is due to item needed not being in stock. The shortage costs include backorder
costs, loss of future sales, loss of customer goodwill, etc.
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MATERIAL PURCHAGE
Material management consists of process of integrating the activities involved in acquisition and
utilization of materials required in the production of final product. Purchasing is the first phase of
material management. Purchasing is responsible for getting the right material, from right place,
in right quantity, at right time and at right price.
Purchase Procedure
The purchase procedure consists of the following stages:
1. Receipt and analysis of requirements from different departments and processing the
requisitions.
2. Selection and location of potential suppliers.
3. Request, receipt and analysis of quotations.
4. Placing of orders.
5. Expediting and following of purchase orders.
6. Verification of venders invoices for payments after processing discrepancies and rejection.
7. Closing of completed orders and maintenance of records.
Methods of Purchasing
The following are some popular methods of purchasing:
1. Purchasing according to requirements-Hand to mouth purchasing.
2. Purchasing for some specified future period.
3.Market purchasing.
4. Rate contract purchasing.
5. Central purchase organization.
6. Rate contract through D.G.S. and D.
1. Hand to Mouth Purchase: used in a job order system, material requirement is worked out
after receipts of order. No inventory is kept. This system has the advantage of less capital
requirements.
2. Purchasing for Specified Future Period: There are standard items which are consumed
regularly. The volume of consumption is low and price fluctuation is not much. These items are
purchased and are available as soon as some order is received.
3. Market Purchasing: Market purchasing helps to take advantage of price fluctuations. The
purchasing is related to price fluctuations and not production needs. There can be loss to the
organization if price fluctuation assessment is wrong.
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4. Rate Contract Purchasing: The organization enters into agreement with various vendors to
supply goods in future periodically on rate contract basis. This method is used for purchase of
large quantities of basic raw materials, like coal, pig iron, paints, cables, etc.
5.Central Purchase Organization: Large government and private organizations have central
purchase system. The requirements from various departments, shops and sections are collected.
The central purchase can be carried out at cheap rates and better bargain.
6. Rate Contract through D.G.S. and D.: The various government departments and other firms
can place orders for the supply of requisite materials at the contract rates approved by
D.G.S. and D.
STORE KEEPING
Storekeeping is the physical storage of goods and materials. The main objectives of storekeeping
are:
1. To make available a balanced flow or raw materials, components, tools, equipments and other
goods necessary to meet operational requirements.
2. To level out irregularities in purchasing.
3. To offset delays in transportation.
4. To provide maintenance materials, spare parts and general stores as required.
5. To add flexibility to production schedule.
6. Permit quarterly purchases which bring lower prices.
7. To ensure right time delivery of finished goods to the customer.
The stores control the stocks and ensure availability of right amount of materials at right time.
The manufacturing departments are not involved with the stock control.
FUNCTIONS OF STORES DEPARTMENT
The following are the main functions and duties of stores department.
1. Identification: Preparation of a code or vocabulary identifying and standardizing of all stocks.
This can be done in collaboration with design, planning and purchase departments.
2. Receipt: Acceptance of all materials and components used in the organization for
manufacturing, maintenance, office, capital goods and finished products.
3. Inspection: Inspection of all incoming consignments for quality either by inspection
department or stores department.
4. Issue and Despatch: Receiving demands, selecting the items and handling over to users. Also
packing of items and loading of vehicle with goods for delivery.
5 Stock Records: Preparation of documents for recording of individual receipts, issues and
balance of stock on day-to-day basis.
6. Stores Accounting: Process of recording details of stocks movement and balance in valuses.
This can be done either by finance department or stores department.
7. Stock Control: Continuously arranging issues a receipts to ensure stock balances are adequate
to support the current rate of consumption.
8. Stock Taking: Physical verification of quantities and conditions of goods in store houses and
stock yards.
9. Storage: Management of store houses and stock yards to ensure proper handling, storage, safe
custody and protection of stock
CODIFICATION AND STANDARDIZATION
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Standardization
Standards are documents containing a set of conditions to be fulfilled. These are technical
publications stating the manufacturing of materials and produces, their measurement, testing and
description.
Industrial standardization is used:
i. To achieve interchangeability or parts.
ii. To lay down the standards of performance of men, materials and tools.
iii. To reduce a line of product to a fixed form, size and characteristics.
iv. To establish standards of excellence and quality of materials.
The standards may be formulated at the following levels:
i.
Individual standards for a dam, house, building, furniture.
ii. Company standards for design, purchase and manufacture of a product.
iii.
Industry standards for a trade or profession.
iv. National standards within a country, i.e., ISI.
v.
International standards between independent sovereign nations, i.e., ISO.
Types of Standards
1. Dimensional standards to ensure interchangeability of parts.
2. Material standards for specification of raw material.
3. Quality/Performance standards of finished products.
4. Technical terms and symbols for a common technical language.
5. Code of practice for operation and maintenance, i. e. , turbines, transformers etc.
6. Safely standards for men, machines and materials, i.e., Boiler Code, Factory Act, 1948.
Advantages of Standards
The following advantages can be achieved by standardization in different fields.
1. Purchasing of materials, parts and supplies.
2. Engineering practices and procedures.
3. Manufacturing processes.
4. Marketing: Sales procedures and techniques.
5. Office management: standard office procedures and practices.
6. Top management: standard policies.
7. Sales: Export market.
Codification
Allocation of symbols for correct classification is called codification. Codes are identification
marks, symbols or references used for classification.
Basic Requirements
1. Code should be as simple as possible.
2. Use numerals for codes, i.e., telephone numbers.
3. Codes should be unique.
4. Coding and decoding should be easily understandable.
5. Codes should be flexible to meet future alterations.
Coding Systems
The coding may be done in one of the following steps:
1. Serially: A serial identification register is prepared.
2. Sequentially: The codes are given in blocks and in sorted form.
Metal sheets: 10,000 to 19999
Nuts and bolts: 20,000 to 29999
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3. Groups: The specification can use a group of digits in code separated by comma (,), a
colon (:) or a dash (-).
ABC Analysis:
ABC Analysis divides inventory into three groups in terms of %age of no. of
items and % age of total value. It is based on Pareto Analysis. In this system important items
(high value items) are grouped in A, While trivial (low usage value) items are grouped in C
and the remaining middle level items are considered B items. The inventory is controlled on
the principle of Management By Exception, i.e. rigorous control over A items and routine
loose control over C items, and moderate control over B items.
The items are classified by virtue of their uses
Category
%age of items
%age value
(approx.)
(approx.)
A High value items
10%
70%
B Medium value items
20%
20%
C Low value items
70%
10%
Steps in ABC analysis:
1. Calculate annual usage in units for each item.
2. Calculate annual usage of each item in terms of Rupees.
3. Rank the items from highest annual usage to lowest annual usage in Rupees.
4. Compute total value.
5. Find %age of high, medium and low valued items.
6. A graph can be plotted between %age useful of on X axis and %age of total value of item
on Y axis.
Controlling of A, B and C items
S. No.
A Class items
High consumption
Value
1.
Very strict control
2.
No safety stock
3.
Frequent ordering
4.
5.
6.
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Weekly control
Statement
Maximum efforts of reduce
lead time
Controlled by top
management
B Class items
Moderate control
Moderate control
Low safety stock
Once in a week
Monthly control
reports
Moderate efforts
Controlled by
middle level
management
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C Class items
Low consumption
Value
Low control
High safety stock
Bulk ordering once
in 6 months
Quarterly control
report
Minimum clerical
efforts
Controlled by
lower level
management
BY: MAYANK PANDEY
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(5) Waste of Stocks: Reduce by shortening setup times and reducing lead times. Reducing all
other wastes reduces waste of stocks.
(6) Waste of Motion: Study motion for economy and consistency. First improve the motions,
then mechanize or automate.
(7) Waste of Making Defective Products: At each process accept no defects and make no
defects.
JIT has the following aims:
a) Purchase supplies just in- time to be used.
b) Produce parts just-in time to be made into sub-assemblies.
c) Produce sub-assemblies just-in-time to be assembled into finished products.
d) Produce finished products just-in time to the sold.
Object of JIT
1. In conventional manufacturing, parts are produced and purchased in batches to serve as
inventory to be used whenever necessary. This approach is a Push system.
2. JIT is a Pull system. The parts are produced or purchased to planned orders. Production
or delivery of parts matches the demand with zero inventories.
3. Workers inspect parts, monitor product quality, correct defects immediately.
4. Worker, engineer and manager work in a team to quickly solve any problem that may
occur during production or assembly. This eliminates further processing of defective
parts.
Advantages of JIT
1. Low inventory carrying cost.
2. Fast detection and correction of defects, low scrap loss.
3. Reduced inspection and rework of parts.
4. High quality parts at low cost.
Results of JIT Implementation
1. Reduction in product cost of 20-40%.
2. Reduction in inventory by 60-80%.
3. Rejection chances less than 10%.
4. Reduction in lead time.
5. Reduction in rejection or warranty cost of 50%.
6. Increase in indirect labour productivity by 60%.
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Supplier
Sub
Contractor
Manufacturer
Supplier
Distributor
Assembler
Retailer
Retailer
C&F
Agent
Supplier
Supplier
Retailer
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ERP
SCM
1.
2.
3.
4.
It generates data
5.
6.
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Support or Secondary Activities in Supply Chain: Porters value chain model for a
manufacturing firm having the five primary activities are supported by four secondary activities.
These are:
(i) Firm Infrastructure: It involves general management, accounting, strategic planning and
control, finance and communication system.
(ii) Human Resource Management: It is basically recruitment, manpower development, training
and managing personnel. etc.
(iii) Technology Development: It involves improvement in product, improvement in process,
improvement in system and R&D etc.
(iv) Procurement: It is basically purchase of raw material procuring machines, and supplies etc.
These secondary activities can support one or more or all primary activities and can also support
each other for an effective value chain.
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