97631664 inventory-management-project-report

INVENTORY MANAGEMENT APEX AUTO LTD.,

EXECUTIVE SUMMARY

G C T M Industry in India has traveled are less, now India is one of the main cotton

manufacturing & exporting cotten in the in india. The cotten in India is with major players and

gadag co operative mill Ltd is one of largest manufacturer of cotten in India.

Inventory is a central process in Manufacturing Unit. This Inventory is concerns to all

departments i.e., from Planning Department to Selling Department in which it passes though

Production Department, HR Department, Logistic Department, Finance Department, Costing

Department, and Commercial Department etc. So managing of Inventory is having wide Scope

in manufacturing Company.

“INVENTORY MANAGEMENT”

Statement of the problem

“Inventory management and its effects on working capital”

Management problem

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Management is feeling that their huge amount of working capital is held up, so the

management wants to know whether they can reduce it through inventory management.

Research problem

As above stated management problem the study was carried to know how inventory

management helps in proper maintenance of working capital, so the title of this study is “

inventory management and its effect on working capital”

Objectives of the study

1. To study the inventory management based on the ratios

2. To find out the impact of inventory on working capital.

3. To study the inventory management and its effective control through various techniques.

4. To suggest the measures for improving the inventory level.

Scope of the study

Inventory management being a very important concept in all the company’s having a

void coverage often calls for the managerial attention. In the modern times inventory

management has become the integral part of the all companies. So all the firm gives special

importance for inventory management. The major objective of the study is to examine the

effectiveness of inventory management system adopted by Akash industry; the study mainly

focuses on the techniques used by the company to control the inventory. The study also covers

other areas like the financial ratios for the period of 2004 to 2007.

SUB OBJECTIVES:

1 To study the different accepts of Inventory Management.

METHODOLOGY

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Primary Data:

1. Interaction with personnel of the company

2. Direct Observation in Inventory

Secondary Data:

1. Balance Sheet

2. Turnover Statements

3. Monthly Inventory Statements

4. Company Records

5. Internet

Tools Used:

MS-Excel has been used for calculations.

INDUSTRY PROFILE

FABRICATION

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When used as an industrial term, applies to the building of machines, structures and other

equipment, by cutting, shaping and assembling components made from raw materials. Small

businesses that specialize in metal are called fab shops.

Steel fabrication shops and machine shops have overlapping capabilities, but fabrication

shops generally concentrate on the metal preparation, welding and assembly aspect while the

machine shop is more concerned with the machining of parts.

METAL FABRICATION

Metal fabrication is a value added process that involves the construction of machines and

structures from various raw materials. A fab shop will bid on a job, usually based on the

engineering drawings, and if awarded the contract will build the product.

Fabrication shops are employed by contractors, OEM's (Original Equipment

Manufacturers) and VAR's (Value-added Reseller) Typical projects include; loose parts,

structural frames for buildings and heavy equipment, and hand railings and stairs for buildings.

1. ENGINEERING

The fabricator may employ or contract out steel detailers to prepare shop drawings, if not

provided by the customer, which the fabricating shop will use for manufacturing. Manufacturing

engineers will program CNC machines as needed.

2. RAW MATERIALS

Standard raw materials used by metal fabricators are;

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Plate Metal

Formed And Expanded Metal

o Tube stock, CDSM

o Square stock

o Sectional metals (I beams, W beams, C-channel...)

Welding wire

Hardware

Castings

Fittings

3. CUTTING AND BURNING

The raw material has to be cut to size. This is done with a variety of tools.

The most common way to cut material is by Shearing (metalworking);

Special band saws designed for cutting metal have hardened blades and a feed

mechanism for even cutting. Abrasive cut-off saws, also known as chop saws, are similar to

miter saws but with a steel cutting abrasive disk. Cutting torches can cut very large sections of

steel with little effort.

Burn tables are CNC cutting torches, usually natural gas powered. Plasma and laser

cutting tables, and Water jet cutters, are also common. Plate steel is loaded on a table and the

parts are cut out as programmed. The support table is made of a grid of bars that can be replaced.

Some very expensive burn tables also include CNC punch capability, with a carousel of different

punches and taps. Fabrication of structural steel by plasma and laser cutting introduces robots to

move the cutting head in three dimensions around the material to be cut.

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4. FORMING

Hydraulic brake presses with v-dies are the most common method of forming metal. The

cut plate is placed in the press and a v-shaped die is pressed a predetermined distance to bend the

plate to the desired angle. Wing brakes and hand powered brakes are sometimes used.

Tube bending machines have specially shaped dies and mandrels to bend tubular sections

without kinking them.

Rolling machines are used to form plate steel into a round section.

English Wheel or Wheeling Machines are used to form complex double curvature shapes

using sheet metal.

5. Machining

Fab shops will generally have a limited machining capability including; metal lathes,

mills, magnetic based drills along with other portable metal working tools.

6. Welding

Welding is the main focus of steel fabrication. The formed and machined parts will be

assembled and tack welded into place then re-checked for accuracy. A fixture may be used to

locate parts for welding if multiple weldments have been ordered.

The welder then completes welding per the engineering drawings, if welding is detailed,

or per his own judgment if no welding details are provided.

Special precautions may be needed to prevent warping of the weldment due to heat.

These may include re-designing the weldment to use less weld, welding in a staggered fashion,

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using a stout fixture, covering the weldment in sand during cooling, and straightening operations

after welding.

Straightening of warped steel weldments is done with an Oxy-acetylene torch and is

somewhat of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will

have a net contraction, upon cooling, in the direction of the sweep. A highly skilled welder can

remove significant warpage using this technique.

Steel weldments are occasionally annealed in a low temperature oven to relieve residual

stresses.

7. FINAL ASSEMBLY

After the weldment has cooled it is generally sand blasted, primed and painted. Any

additional manufacturing specified by the customer is then completed. The finished product is

then inspected and shipped.

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COMPANY PROFILE

Name of the company : APEX AUTO LTD

Address of the Head office : M-1 phase- VII, TATA kandra main road, industrial

area ADITYAPUR, JAMSHEDPUR-832109 INDIA.

Fax: 0657-2200010

Tel: 91-657-2408715, 2409041 & 2381346

E-mail: [email protected]

Address of the registered : Nataraj mansion, Bistapur- 831001,

Office JAMSHEDPUR, INDIA

Fax: 91-657-2424526

WEBSITE: www.apexautoltd.com

Address of the UNIT II : APEX AUTO LTD (UNIT II) Block no: 2

Dharwad Telcon premises, K.I.A.D.B, P.B. Road

Dharwad- 580007, India

Fax: 0836-3293214

Tel: 0836-3293214

E-mail: [email protected]

Nature of the organization : Basically this company is heavy fabrication

Company. They are manufacturing back hoe

Loader components and excavator

Components

Type of organization : Apex auto limited company is private limited

Company

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mailto:[email protected]


ABOUT ORGANIZATION

Apex Auto Limited ("If you can imagine it, We can fabricate it.")

Apex Auto Limited is a publicly quoted company with a number of shareholders, both

Indian and Foreign. Promoted by Mr. Atul Taunk in 1995 with a modest capital outlay of Rs. 342

lakhs, Apex today has a capital outlay of Rs. 1200 lakhs. A growth of over 350% per annum.

Achieved by producing thousands of dynamically stressed machined components for the

construction equipment industry

The raison deter of Apex is that the emerging scenario in post liberalized India indicated

that the nation was poised to go in for massive infrastructure building: roads, super highways,

ports, power projects, and so on. This would put immense pressure on manufacturers of earth-

moving equipment. Apex eases the load on them by supporting the industry with precision

engineered sub-assemblies and major assemblies that can go directly into their equipment, such

as revolving frames, main frames, booms, arms, dozers, buckets, and so on.

As a case in point, we're proud to have been entrusted with the single share of business

for all major fabrications that go into the making of TATA Hitachi's top selling excavators, the

EX-60. Over the last 5 years, we have fabricated more than 10,000 components of this particular

model alone.

VISION

To be recognized as a premier QUALITY manufacturer and supplier fabricated components,

embodying thus the spirit of commitment and humanity.

MISSION

As per customer schedule requirement fulfill it, Deliver on time, every time.

An eye on product quality and integrity

Highest productivity, thereby offering a cost advantage to all our clients.

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Why Apex?

Aristotle - Greek inventor of the Science of Logic - recommends studying the theory of 'The 4

Becauses' before making your choice Why Apex for your Machined fabrication ?

The 1st because deals with what is it made of ?

Apex uses only prime quality steel sheets and plates procured from leading players in the

industry - Tata Steel and SAIL.

The 2nd because deals with how is it made ?

Apex has state of art Material Processing facilities including Indias largest laser cutting

machine. And excellent Production Engineering systems set up by a highly experienced and

technically qualified team of engineers.

The 3rd because deals with what is made ?

Based on our customer's drawings and design, Apex manufactures dynamically stressed

machined fabrications conforming to all the specifications laid down by the customer.

The 4th because deals with why is it made thus ?

Apex follows the first three precepts so that the end customer gets a world-class product

which will withstand the ultimate test of time.

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KEY AWARDS WON

For safety in manufacturing process awards (less accident in manufacturing process) for

continuous 3 years form Telco construction equipment limited

For MINIMUM REJECTION award form Telco construction equipment limited

SWOT Analysis of the Company

APEX AUTO LID KEY STRENGTHS

1. STRONG PRODUCT DEVELOPMENT

As per the specification from Telcon the new product is been developed

1. By the highly qualified internal engineering department

2. STRONG MERCHANDISING TEAM

Technically qualified and high skilled Merchandising department is another asset of the

company, who plays a major role in executing the orders utmost efficiently to the satisfaction of

Buyers.

3. PROFESSIONALLY MANAGED:

a) Company has two units in Dharwad, one is Apex auto Ltd Unit I and the other is Apex auto

Ltd Unit II

b) Unit I is headed by Mr. Arvind Gaur, Unit II is headed by Mr. Pravat Kumar Rath

4. FACTORIES ENGINEERED TO PRODUCT SPECIFIC:

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All their manufacturing units are engineered to product specific and managed by effective

and efficient internal engineering department.

5. QUALITY CONTROL SYSTEM:

There is an independent quality audit team in process control system in all the factories,

which has given quality production consistently.

6. SOURCING OF RAW MATERIALS UNDER VIGILANCE OF QUALITY

AUDIT SYSTEM:

They source all their raw materials 100% from within India. However, they have a rigid

control on their quality control system where by they ensure that all the raw materials are

produced as per their quality standard level before it gets dispatched to their factories.

7. IN HOUSE LAB:

They have a lab situated in the major procurement centers, such as in Dharwad and

Jamshedpur to support their quality control team to carryout the various quality tests at all level

onwards to ensure that the product is produced according to their quality in-house.

8. PRE-SHIPMENT INSPECTION TO MAINTAIN ZERO-CLAIM FROM

BUYERS:

A thorough Inspection by In-house Quality Control team and pre-shipment Inspection by

buyer representative for all their products helps company to maintain zero-quality claims

position with all their buyers.

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9. CONFIDENCE OF THEIR BUYERS:

All the buyers as of today have been working with them since decades and they started with

them on continues basis with enhanced volume. This has given them huge confidence as the

confidence level of their buyers is very high in their products, quality, timely deliveries and

commitment towards work.

They have been awarded for 3 consecutive years for minimum rejection and for safety in

process of manufacturing by Telco construction equipment limited

APEX AUTO LTD WEAKNESS

No such entity has been identified so far.

APEX AUTO LTD KEY OPPORTUNITIES

Chances to get more products to manufacture form the Buyer i.e. Telcon construction equipment

limited

APEX AUTO LTD KEY THREATS

More-qualified competitors

CUSTOMER NAME

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Apex auto ltd unit II has having only one customer that is TELCON CONSTRUCTION

EQUIPMENT LTD

SUPPLIERS NAMES

SUPPLIERS NAME LOCATION

A005 AKSHATA ENTERPRISES, HUBLI

A013 ASHA ELECTRICAL & SALES HUBLI

A045 ADITYA ELECTRICAL SALES CORPORATION HUBLI

A051 ANAND AIRLINE ACCESSORIES HUBLI

A052 ABHI ENGINEERING WORKS BANGALORE

A058 AMAR ELECTRICAL WORKS HUBLI

A063 ANDANUR PIPES DISTRIBUTORS DHARWAD

B031 BELGAUM CNC APPLICATIONS PVT. LTD BELGAUM

B036 ESHAK DADA BAMBOOWALA MUMBAI

B038 B. MAHENDRA & BROS DHARWAD

B041 BASAVESHWAR KHANAVALI DHARWAD

B044 BELUR INDUSTRIAL GASES DHARWAD

B045 B.B. ENTERPRISES HUBLI

C003 CHACHRA SERVIUCES JAMSHEDPUR

C004 CHAITANYA SALES PVT. LTD. JAMSHEDPUR

D019 DYNAMIC DRIVES HUBLI

D020 DELTA FURNITURE PRIVATELIMITED CHENNAI

E027 EUREKA FORBES LTD DHARWAD

F003 FABRO-TECH ENGINEERS DHARWAD

G008 GOUTAM MACHINE TOOLS HUBLI

G026 GAYATRIMATA INDUSTRIES DHARWAD

H010 HYDROPACK(INDIA) PVT LTD BELGAUM

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I018 INDUS MARKETING BELGAUM

J003 JKAY ENTERPRISES HUBLI

K007 KAMATH ENTERPRISES BELGAUM

K008 KAPILA MARKETING DHARWAD

K010 KARNATAKA MATERIAL TESTING RESEARCH BELGAUM

K036 KULKARNI BOOK STALL & STATIONERIES DHARWAD

M008 MARUTI INDUSTRIAL SERVICE CENTRE BANGALORE

M017 MADRAS HARD TOOLS PVT LTD CHENNAI

M019 MANJUNATH GARMENTS DHARWAD

N016 NAVYA ENTERPRISE HUBLI

O003 OMEGA FABRICATIONS DHARWAD

P002 PETHE BRAKE MOTOR PVT. LTD RATNAGIRI

P006 PRAXAIR INDIA PVT LTD BANGALORE

P028 PRESSURE CONTROL EQUIPMENT KOLKATTA

P037 PAVAN ELECTRICAL COMPANY HUBLI

R001 R.R. ASSOCIATES HUBLI

R007 RENUKA ENGINEERING WORKS DHARWAD

R035 RITTAL INDIA PVT LIMITED BANGALORE

S019 SONA STEEL ENTERPRISES MUMBAI

S085 SAKSHAM AUTOMATION SYSTEMS HUBLI

S087 SHREE GANESH GAS IMPLEMENTS AND SER HUBLI

T001 TARACK ENGG SERVICES DAVENGIRI

T003 TECHNO COMMERCIAL CORPORATION JAMSHEDPUR

T031 TATA STEEL LIMITED BANGALORE

V001 VALJI & BROTHERS HUBLI

V007 VIJAYSHEER DISEL SALES AND SERVICES HUBLI

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V008 VOLTAS LIMITED BANGALORE

V014 VIKAS VIDHUTIKARAN PVT LTD DHARWAD

W006 WELD INDIA CONSULTANCY DELHI

Y003 YALLAPPA HEGGERI DHARWAD

Apex Auto Ltd Unit II is having a numerous suppliers. They mainly purchase Raw

Materials like MS plates, Bush Stoppers, Seat Curve etc from Indian suppliers.

ORGANIZATION STRUCTURE

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Administration Assistant

Production department

Head

Supply Chain Mgmt Head

Quality Assurance

Head

WorkersSubordinateMembers

Store Supervisor

Production Supervisor

Machine Operators

Machine Department

Head

AssistantQ. A

Helpers

ProductionAssistant General

Manager

Human ResourcesAssistant General

Manager

C E O

General Manager

Production Planning & Control Manager

Finance Manager

Managing Director


1. Personnel Department

This department is almost like a human brain, since it is the human beings that operate it.

This department is concerned with implementation of the plans, with the welfare of the plant,

with the industrial relations and above all safety and security of the plant and the work force is its

prime concerns. This department looks after the subsidiaries like recruitment selection training

and induction, canteen, community development disciplinary actions etc., welfare, security,

guesthouse, medical facility etc., (As per Indian Factories Act 1948.)

Team Apex Professionally managed with a rich blend of experience and enthusiastic

youth, Engineers, Diploma Holders, draft men, ITI welders and fitters, Gas cutters, workers and

Fabrication Experts.

Let’s go through the process of the Recruitment in Apex Auto Ltd Unit II.

Recruitment is process of searching the prospecting candidate, stimulating and

encouraging them to apply for the job. The above meaning says that every organization want

skilled workers so Apex Auto Ltd Unit II also recruit candidates as follows , they firstly check

the organization culture which type of employees needed in organization and they also check

employment condition in unit.

They are searching the candidates in two ways one is Advertisement and the other is

manual searching. In advertisement they give firstly the adz’s like Draft Adv, Client review adv

and Place adv, and then they receive the calls then access their CV’s. In manual searching

process they search the employee in plan search, identity search, and contact search, then they

check the candidates interest after that they arrange meeting for selection process

Selection process Selection is a process of checking the candidate’s knowledge,

behavior, Skills, experience, and qualifications etc to select and place the candidate their correct

position.

2. Stores Department

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The raw materials are stored separately under material cell in production department; as

per the demand this department does the work of receiving and issuing of materials.

3. Purchase Department

Against the approved purchase requisition the department purchases of raw material semi

finished goods and Accessories and other needs of the various departments. In order to make the

work efficient it has the system of sub contractors. So the purchase department does the creation

of sub contractors and vendors. This department is guided by the main motto the plant and other

departments working. Let’s have a look on the flow chart of the purchase of raw materials in

Apex Unit II

4. Dispatch Department

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Quotations request to one or more vendors according to requirement

Quotations Comparisons

Best Negotiation

Purchase Order creation

Purchase Order send to vendor (supplier)

Follow Up and procure the material for production

Material indenting(As per customer

schedule)


The dispatch of materials and finished goods is done in a very efficient way.

5.Production Department

This department entrusted with the task of the production of Dozer Blade, Loader

Bucket, Narrow Bucket, Back Hoe Main Frame, Boom, Arm, Counter Weight, Heavy Duty

Bucket, Revolving Frame and Track Frame. From our very inception at Jamshedpur in 1996 and

at Dharwad in 1999, our infrastructural facilities have been meticulously planned out with an eye

towards satisfying the exacting standards of world class players in the Earth Moving Industry.

Let’s have a look on the process of manufacturing process in Apex Unit II, basically this

company is heavy fabrication company, they are manufacturing BACK HOE LOADER

COMPONENTD & EXCAVATOR COMPONENTS. Following are the components. JHON

DEER (JD) Boom, Arm, Loader Arm and EXCAVATORS 70, 110, 120, Boom and

EXCAVATORS 70, 110,120 Arm. The below showing is the manufacturing process of

Excavators-70 Boom.

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Flow chart of Excavator – 70

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CONTINUE

ASSEMBLY OUT OF FIXTURE

TA 00233/02

SETTING

LEFT OVER WELDINGTA 0233/26

FIT AND WELD

ROBOT WELDING

Rejection/ Rectification

INSPECTIONTotal length 3720+/- 4mm

Top lug distance WRT Boom End Bracket, Bottom lug

distance

=

CONTINUE

OUT OF FIXTURE2ND STAGE WELDING

IN FIXTURETA 00233/09, TA 00233/10

TA 00233/04

LUG FITTINGTA 00233/14, TA 00233/15,TA 00233/16, TA 00233/17,

CONTINUE

2ND STAGE ASSEMBLYTE 20789, TE 20790

TA 00233/03

OUT OF FIXTURE1ST STAGE WELDING

IN FIXTURESUB ASSEMBLY 1ST STAGETA 01164/00, TA 00233/27, TA 00233/01, TA00233/08,TA00233/05, TA00233/06

TA00233/07

BOOM END BRACKET ASSEMBLY

TC 00558/01(RH), TC 00558/02(LH)

BEVELING OF PLATESTA 00233/01, TA22033/07,

TA 00233/08


Not Ok

OK

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Not Ok

OK

Not Ok

OK

Not Ok

OK

Manufacturing process of Ex-70 Boom

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MACHINING

DESPATCH

RECTIFICATION

REJECTION/ RECTIFICATION

REJECTION/ RECTIFICATION

INSPECTIONUT TESTING

DRESSING

INSPECTION

INSPECTION

CONTINUE


Manufacturing process of Ex- 70 Boom is having several steps already you know

in the flow chart now below showing manufacturing process in detail

1. RAW MATERIALS

In every manufacturing process raw materials must required there for APEX AUTO

LTD (UNIT II) purchase raw materials from its main branch at JAMSHEDPUR and form Apex

Auto Ltd (Unit I). Some materials directly comes to Unit II but some materials firstly comes to

Unit I and after some process it is send to Unit II. Then the stores department sends materials to

production department for production

2. BOOM AND BRACKET ASSEMBLY

In this process Boom and Bracket assembled or produced. Here firstly they join

20mm Bkt Plate (RH) (TC 00558/01) and TA00233/22 according to the diagram. Then they join

20mm Bkt Plate (LH) (TC 00558/02) and TA 00233/11. After that back up bars are join at the

bottom of both 20mm Bkt plates. Then these two jointed by the plate Back up plate (TA

00233/19), then they join one square plate for maintaining required dimensions after welding of

all this parts this complete the manufacturing of Boom And Bracket Assembly.

3. BEVELING OF PLATES

Some plates beveled by Unit I and those plates are Top rolling plate(TA 00233/01),

Side bend plate LH(TA 00233/07) and side bend plate RH(TA 00233/08)

4. IN FIXTURE SUB ASSEMBLY 1ST STAGE

In this process one sub assembly will be done in this stage BOSS (TD01164/00) is

joined to Top rolling plate (TA 00\233/01) at one side then at the top of the BOSS they join Side

bend plate LH (TA 00233/07). After that inside of the BOSS they join BOSS Back up Plate (TA

00233/27). Then in the middle of Top rolling plate and Side bend plate they join Gasset

plate(TA00233/05) and near to that Bend Gasset plate is joined with required dimension, after

that Side bend plate RH(TA 00233/08) is joined according to diagram so this complete Sub

assembly first stage.

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5. OUT OF FIXTURE FIRST STAGE WELDING

After completion of Sub assembly first stage each part is manually weld in this

process.

6. SECOND STAGE ASSEMBLY

In this process Back up bar (TE20789) 03 Back up bar(TE20790) are attached in

the inside part of Bottom rolling plate (TA00233/03) at the right side with required dimension

according to diagram

7. OUT OF FIXTURE

In this process second stage welding process is done manually.

8. IN FIXTURE

In this process firstly prepared Boom and Bracket is joined by using plates such as

Cover plate 6mm (TA00233/09) and Cover plate 8mm (TA00233/10), after that there is some

place which is empty so that place is been filled by plates Taper side Plate(TA00233/04) 2 plates

according to diagram. So this process finishes boom and bracket assembly.

9. LUG FITTING

In this process Lugs are fitted to the prepared component which are Top lug and

bottom lugs and Top washers lugs and Bottom washer Lugs. Firstly bottom lugs are joined to

each other and then those lugs are attached to the bottom of the prepared component. After

joining the bottom lugs the top lug is joined to the top of prepared component with required

dimension or space so as to complete this process.

10. INSPECTION

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This is an important stage in manufacturing process. In this stage they check total

length of the component. Total length should be 3720mm if there less difference of 4mm then

there is no problem it must not exceed 4mm, then they also check centre point of the component

and top lug distance to the boom and bracket, and bottom lug distance of the components if there

is any problem found then they go for rectification of the component.

11. ASSEMBLY OUT OF FIXTURE

In this process they join one Top cover plate (TA00233/02) to the boom or prepared

component according to the standard diagram and they also join ‘M’ plate (TA00233/28) attach

to the top lugs so this completes the process of assembly.

12. ROBOT WELDING

Robot is a programmable multiplication, manipulate design to material part, tools

or specialized devices are t

o carry out specific task.

In Robot welding processed components are weld by Robot machine. Firstly they

set the programs to the robot for welding the components. Every component has is its own

welding program according to the standard drawing of the components, after installation of the

Ex – 70 program the welding process of EX- 70 boom starts, Mig welding wire is been used by

the robot to weld the component.\

13. LEFT OVER WELDING

After completion of the Robot welding there are some spaces left which are weld

manually by welders. In this process they also join BOSS Reenforcement plate (TA00233/26) at

the top and bottom side of the BOSS according to the diagram.

14. SETTING

In this process they maintain required dimension in various parts of the components

through the gas heating which includes Organ and Co

15. INSPECTION

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In this process they measure the components by using measuring scale, try square,

Vernier and gauges etc.

16. MACHINING

Machining process means removing the rough face as per the standard drawing. In

machining process they have two type of jobs one is milling and the other is boring, in this

process they are using two type of machines one SHW that means hidden control machine and

the other is Fanuc control machine. To reduce heat in the process they are using coolant oil

because it helps to reduce the heat for insert ware and tear and it helps to smooth milling and

boring of the component in machining they are having there stages

1. Rough stage

2. Semi finish

3. Finish Stage

In Ex- 70 boom components are having mainly four bores boss bore must have the size of 75mm

and lug bore must have the size of 55mm and bracket must have 60mm.

17. INSPECTION

In this process they use the following instruments to check weather the machining

process is properly done or not

1. Bore dial gauge

2. Micrometer

3. Vernier

4. Measuring scale etc

18. DRESSING

Dressing is the very important stage in manufacturing process in this process they

clean the components by using grinding machine and sander machine to remove spatters chips

etc, here they also fit some items to prepare components to according to standard diagram.

19. INSPECTION

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In this process they are checking welding defects in the components by using

Ultrasonic Technique (UT) machine, the following are the defects we can find by using UT

machine.

1. Blow Holder area

2. Proper penetration

3. Porsity etc

20. DISPATCH

After completion of all this processes the quality assurance department checks the

quality of the component and after checking they finally dispatch the product so this complete

the manufacturing process of EX-70 boom model.

Apex Auto Limited is in the service of gaints in the field of Excavator

manufacturing Co. TELCON for 6 Years by maintaining a high QUALITY & SKILL. And for

its efforts, it has been certified by TELCON, and other quality maintaing institutions.

INVENTORY MANAGEMENT

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Management of inventory assumes importance due to the fact that investment in

inventory constitutes one of the major investments in current assets.

The term inventory refers to the stockpile of the products a firm is offering for sale and

the components that make up the product. The assets which firms store as inventory in

anticipation of need are:

(i) Raw Materials:

These represent inputs purchased and store to be converted into finished products in

future by making certain manufacturing process on the same.

(ii) Work in Process:

These represent semi-manufactured products which need further processing before they

can be treated as finished products.

(iii) Finished Goods:

These represent the finished products ready for sale in the market.

(iv) Stores and Supplies:

These represent that part of the inventory, which does not become a part of final product

but are required for production process. They may be in the form of cotton waste, oil and

lubricants, soaps, brooms, light bulbs etc. Normally, they form a very minor part of total

inventory and do not involve significant investment.

Let us have a look on Different Inventory Management Views. Means emphasis role of

Inventory Management in different Sectors.

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Inventory Management is consisting of 3 hands. The first hand as shown in the diagram

is that Physical Inventory Management, Second one is Financial Inventory Management and the

last one (third one) is Logistic Inventory Management.

The reason behind of dividing these views is: to gather the information very easily and

for easy to understanding of each view thoroughly. Let us see the Meanings of each view one by

one.

Physical Inventory Management

Meaning:

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Physical Inventory Management

Financial Inventory Management

Logistic Inventory Management

INVENTORY MANAGEMENTINVENTORY MANAGEMENT

3

VIEW

S


“Keeping of goods is also a type of management. Whenever requirements comes from

the production department, providing of those required materials in a proper manner & providing

those at the specified period, is the main motto of Physical Inventory Management.”

Benefits for Holding Inventory :

Benefits in Purchasing

Benefits in Production

Benefits in Work-in-Process

Benefits in Sales

Objects of Inventory Management:

Usually, the company is faced with the following conflicting objectives in the area of

inventory management:

1. To carry maximum inventory in order to facilitate efficient and smooth production

and sales operations.

2. To minimize investment in inventory for maximize the profitability.

Both over-investment and under investment in inventories is undesirable as both involve the

consequences. The over-investment involves the consequences like:

i) Unnecessary blocking of funds in inventory and hence loss of profit.

ii) Excessive storage and Insurance Cost.

i. Risk of liquidity. The inventories once purchased and stored are normally difficult to

dispose off at the same value.

The under-investment involves the consequences like:

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b. If sufficient stock of raw material and work in process is not available, it may result into

frequent interruptions in production.

c. If sufficient stock of finished goods is not available it may not be possible for the

company to serve the customers properly and they may shift to the competitors.

Thus, it can be said that the objective of inventory management is to minimize the

investment in inventory without affecting production or sales operations.

Inventory, as a current asset, differs from the other current assets because only financial

managers are not involved. Rather, all the functional areas, finance, Marketing, Product &

Purchasing are involved.

The job of the financial manager is to reconcile the conflicting viewpoints of the various

functional areas regarding the appropriate inventory levels in order to fulfill the overall objective

of maximizing of owner’s wealth.

Two-Bin System:

Under this system, the inventory items are grouped into two categories. In one group or

bin, sufficient quantity is kept to meet the current requirements over a designated period of item.

In another group or bin, a safety stock is maintained to meet the requirements of inventory at

times when the stock in the first bin is exhausted and re-ordering occurs.


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Meaning:

“Recording, maintaining and evaluating of stocks in a value terms is known as Financial

Inventory Management.” In other words valuation of stocks, and controlling of ordering and

holding costs and also maintaining of sufficient valued stocks in Inventory is known as Financial

Inventory Management.”

Financial Inventory Management is again divided into three different categories.

1) Based on Valuation

2) Based on Cost Analysis

3) Based on Financial Statement

1) Based on Valuation

There are number of generally accepted methods of determining the cost of inventories at

the close of the accounting period. The selection of a suitable method assumes significance in

view of the fact that it has a direct bearing on the cost of goods sold and consequently on profit.

Therefore, the method should be selected in the light of probable effects on profits over a period

of years.

Note:

It may not be out of place to mention that once a method is selected, it must be used

consistently and cannot be changed from year to year.

The discussion here of the methods to value inventory should, therefore be viewed in this

perspective.

First In First Out (FIFO) Method:

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The FIFO method of valuation of inventory is based on the assumption that the inventory

is consumed in chronological order, that is, those received first are issued/consumed first and

value fixed accordingly. The merit of FIFO method is that the physical flow of materials

matches the flow of cost.

Last in First Out (LIFO) Method:

Under the LIFO method, the cost of goods sold and the value of closing inventory can be

determined only after the final lot of the year has been received. This is because of the

assumption underlying the valuation of inventory, according to this method. As the name LIFO

suggests, the use of inventory is valued on the basis of the inverse sequence of receipts. Since

the LIFO method assumes that the latest item in is the first item out, the current cost of materials

are matched with the current selling price/current revenues. This matching of current costs with

current revenues is the essence of the argument for the LIFO method.

Average Cost Method:

According to average cost method, each purchase is added to inventory and an average

cost determined. Materials are charged into cost of sales at this average until another lot is

received, when a new average unit inventory cost is calculated.

Note: There are so many other than these above methods but most wide usefully methods are

these three so here we discussed those three methods only.

2) Based on Cost Analysis

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Cost of Holding Inventory: -

One operating objective of inventory management is to minimize cost. Excluding the

cost of merchandise, the costs associated with inventory fall into two basic categories: (i)

Ordering or Acquisition or Set-up Costs, and (ii) Carrying Costs. These costs are an important

element of the optimum level of inventory decisions.

1) Ordering Cost :

It is the fixed cost of placing & receiving an inventory order. Like (a) Preparing a purchase

order or requisition form & (b) receiving, inspecting & reordering goods received to ensure both

quantity & quality. It is also called as setup cost.

2) Carrying Cost :

The second broad category of costs associated with inventory is the carrying costs. They are

involved in maintaining or carrying inventory. The cost of holding inventory may be divided

into two categories.

1. Those that Arise Due to the Storing of Inventory: The main components of this

category of carrying costs are (i) storage cost, that is, depreciation, insurance,

maintenance of the building and utilities; (ii) insurance of inventory against fire and theft;

(iii) deterioration in inventory because of pilferage, fire, technical obsolescence, style

obsolescence and price decline; (iv) serving costs, such as labour for handling inventory,

clerical and accounting costs.

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2. The Opportunity Cost of Funds: This consists of expenses in raising funds (interest on

capital) to finance the acquisition of inventory. If funds were not locked up in inventory,

they would have earned a return. This is the opportunity cost of funds or the financial

cost component of the cost.

Linking of Costs based and Physical Based Inventory Management:

The carrying costs and the inventory size are positively related and move in the same

direction. If the level of inventory increases, the carrying costs also increase and vice-versa.

Total Cost:

The sum of inventory increases, the carrying costs represent the total cost of inventory.

This is compared with the benefits arising out of inventory to determine the optimum level of

inventory.

Economic Order Quantity (EOQ):

How much inventory should be bought in a lot? Should the quantity to be purchased be

large or small? Should the requirements of material during a given period (say 6 months or 1

year) be acquired in one lot or should it be acquired in installments or in several small lots?

Such inventory problems are called Order quantity problems.

Therefore EOQ is that level of inventory at which total cost of inventory comprising

ordering cost & carrying costs is the minimum

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Formulae for calculating Economic Order Quantity:

EOQ = 2AO

C

Where,

A= Annual Quantity

O= Ordering Cost

C= Carrying Cost

Assumptions:

1. The firm knows with certainty the annual usage (consumption) of a particular item of

inventory.

2. The rate at which the firm uses inventory is steady over time.

3. The orders placed to replenish inventory stocks are received at exactly that point in

time when inventories reach zero.

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Order Point:

Reorder Point:

This is the point at which to order inventory-expressed equation-ally as:

Lead Time in days X daily usage.

Lead Time:

It is the time normally taken in receiving delivery after placing orders with suppliers.

Safety Stock:

It implies extra inventories that can be drawn down when actual lead-time and/or usage

rates are greater than expected.

3) Based on Financial Statement

For having assistance by banks, bankers should first evaluate the followings:

1. Collateral Strength.

2. Inventory Position

3. Some Financial Ratios

4. Payment of all requirements like Income Tax, Wealth Tax, Interests on debt etc.,

5. Agreement papers of all authorized persons like Debenture holders, Shareholders etc.,

6. All required documents.

7. Who is the Buyer and his Country’s relationship etc,

The main requirement for Banker is the Financial Statements of 3 to 5 years. From this

statement it can judge the financial strength of the Company. While analyzing of Financial

Strength of the Company, Inventory is also having its own emphasis role. Because if company is

having less inventory than its requirement then company will get less finance from Banks and

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visa-versa. So here high inventory means, high in the sense company should have sufficient

inventory according to its order. Not more than its order.

Let us have a look on some Inventory related Ratios and also some important financial

ratios those, which are related to Inventory. From evaluating of these Financial Ratios, company

can judge the stocks/goods level in Inventory, so that company can get loan from Banks.

The financial statement provides a summarized view of the financial position and

operations of a firm. Therefore, much can be learnt about a firm from a careful examination of its

financial statements as invaluable documents/performance reports. The analysis of financial

statement is, thus an important aid to financial analysis.

The analysis of financial statements is a process of evaluating relationship between

component parts of financial statements to obtain a better understanding of the firm’s position

and performance.

Tasks of Financial analyst is to:

1) Select the information relevant to the decision under consideration from the total

information contained in financial statement.

2) Arrange the information in way to highlight significant relationships.

3) Interpretation and drawing of inferences and conclusions.

In brief, financial analysis is the process of selection, relation and evaluation.

Financial analysis is the process of identifying the financial strengths and weaknesses of

the firm by properly establishing relationships between the items of the balance sheet and the

profit and loss account. Financial analysis can be under taken by management of the firm, or by

parties out side the firm, viz., owners, creditors, investors and others. The nature of analysis will

differ depending on the purpose of the analyst.

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Management of the firm would be interested in every aspect of the financial analysis. It

is their overall responsibility to see that the resources of the firm are used most

effectively and efficiently, and that the firm’s financial condition is sound.

Trader creditors are interested in firm’s ability to meet their claims over a very short

period of time.

Investors, who have invested their money in the firm’s shares, are most concerned about

the firm’s earnings.

Suppliers of long-terms debt, on the other hand are concerned with the firm’s long-term

solvency and survival. They analyze the firm’s profitability over time, its ability to

generate cash to be able to pay interest and repay principal and the relationship between

various sources of funds.

2.Ratio Analysis related to Inventory

Ratio analysis is a powerful tool of financial analysis. A ratio is defined as “the indicated

quotient of two mathematical expressions” and as “the relationship between two or more things.”

In financial analysis ratio is used as a benchmark for evaluating the financial position and

performance of a firm. Ratios help to summarize large quantities of financial data and to make

qualitative judgment about to form a qualitative judgment the focus of financial analysis is on the

key figures in the financial statements and the significant relationships that exist between them.

Types of Ratios:

a. Liquidity Ratios

b. Activity Ratios

c. Profitability Ratios

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A. Liquidity Ratios:

Liquidity refers to the ability of the firm to meet its obligations in the Short run, usually

one year. Liquidity ratios measure the ability of the firm to meet its current obligations.

Liquidity ratios by establishing a relationship between cash and other Current assets to Current

obligations provide a quick measure of liquidity. A firm should ensure that it does not suffer

from lack of liquidity, and also that it does not have excess liquidity.

Therefore it is necessary to strike a proper balance between high liquidity and lack of

liquidity. Following are some of the important liquidity ratios:

1. Current Ratio

2. Quick Ratio

3. Net working Capital Ratio

B. Activity Ratios:

Activity ratios are concerned with measuring the efficiency in asset management.

Sometimes, these ratios are also called efficiency ratios or asset utilization ratios. The efficiency

with which, assets are converted into sales. The greater the rate of turnover or conversion, is the

more efficient the utilization. For this reason, such ratios are also designated as turnover ratios.

Turnover is the primary mode for measuring the extent of efficient employment of assets by

relating the assets to sales. An activity ratio may, therefore, be defined as a test of the

relationship between sales and various assets of a firm. Several activity ratios can be calculated

to judge the effectiveness of asset utilization.

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1. Inventory Turnover

2. Assets Turnover

3. Fixed Assets and Current Assets Turnover

Asset Measurement for different methods of inventory valuation:

FIFO Method:

Under this method, as noted earlier, inventory is valued on the assumption of

chronological cost flow. This implies that the unused/unsold inventory consists of the most

recent purchases and, therefore, can be assumed to be valued at current cost. The vale of

inventory as show in the balance sheet would reflect the current cost, if FIFO method were used.

LIFO Method:

According to this method, obviously, the inventory figure would not appear in the

balance sheet at the Current Cost. It will reflect rather the cost of raw materials purchased in the

past year. Assuming rising prices, the inventory value based on the LIFO method would tend to

be undervalued. For example inventory purchased as early as six years or more. In that

situation, the inventory figure included in the balance sheet would be actually the price paid on

the purchase of inventory six years ago. In a period of rising prices, this value would naturally

be grossly out of line with the currently prevailing price. This would imply that the balance

sheet would not reflect the current worth of the inventory. That the inventory value will not be

correct is another way of saying that the balance sheet will present a distorted picture of the

affairs of the firms.

A possible solution to correct the above distortion in the balance sheet implicit in the

under-valuation of inventory with the LIFO method is a modified/adjusted LIFO method.

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The modified method will, thus, serve the needs of correct income determination as well

as correct asset measurement. However, this is subject to a qualification, namely, the current

year’s purchase (units) should exceed the current year’s consumption (units). If for reasons such

as strike/lockouts, transportation problems, and so on, the current consumption exceeds the

current purchases, profits will rise. The increase will depend upon the extent of liquidation of

the previous years’ inventory. This increase in profit is termed as liquidation profit, which is

equal to the difference between the current cost of inventory and the cost of inventory purchased

in the past.

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Logistics Inventory Management

Meaning of Logistics:

Logistics is the Organization of Services and Supplies. In other words, logistics is

making and taking the permission for sell/exporting the company’s products in foreign countries.

In fully export-oriented business this is one of the main department, where this

department gets an approval to sell their goods in foreign countries. And also their main

intention is to maintain all documents of those that are related to the exporting of their products.

Logistics Inventory Management:

Yes, already we have observed about the meaning of Inventory Management in the

Organization. But in fully export oriented business; Inventory Management is a very important

concept. Because every exporter or importer, they do not know about each other who are staying

in other countries.

So every company, which are exporting or importing of materials, they should

communicate each other through banks only. These banks are listed by Central Bank of that

Nation. In our Country RBI is lists some banks for intermediating purpose and every year RBI

declare some listed Banks as a mediator.

For producing of materials and selling of those materials, every company/business should

need a Working Capital. This Working Capital can also financed by Banks. While in export

oriented business it is slightly different task. Here Banks can acts as financial assistance for Pre-

Shipment and for Post Shipment of Goods.

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For having an assistance by banks they should first evaluate followings:

1. Collateral Strength.

2. Inventory Position

3. Some Financial Ratios

4. Payment of all requirements like Income Tax, Wealth Tax, Interest etc.,

5. Agreement papers of all authorized persons like Debentures, Shareholders etc.,

6. All required documents.

7. Who is the Buyer and his Country’s relationship etc,

Before going to detail decision on Banks let us have a look on Commercial Papers. Which are

also parts of financing the working capital requirements of the Companies.

Commercial Papers (CPs):

In the recent past, Commercial Papers (CPs) have become one of the best methods for

financing the working capital requirements of the companies.

The companies trying to raise the funds by issuing the CP are regulated by Guidelines for

issue of Commerical Papers (CP), 2000 issued by Reserve Bank of India on October 10, 2000.

These guidelines apply to the companies trying to raise the funds by issuing the CPs. As per

these guidelines, a a company means a company as defined in section 45-I(aa) of Reserve Bank

of India Act, 1934. Section 45-I(aa) of Reserve Bank Act, 1934 defines a company as the

company as the company as defined in section 3 of the companies Act, 1956.

In the Indian circumstances, banks play a very major role in financing the working capital

requirement of the organizations. We will consider the bank as a source for financing the

working capital requirement of the organizations under the following heads:

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Amount of Assistance

To obtain the bank credit for financing the working capital requirements, the company is

required to estimate the working capital requirement properly. To estimate the requirement of

working capital requirement properly, the company will be required to estimate its level of

current assets and current liabilities properly, as working capital is the difference between current

assets and current liabilities.

For this, the techniques like ratio analysis, trend analysis etc., can be used by the

company. More accurate the estimation of the level of current assets and current liabilities, more

accurate the estimation of level of current capital. Then, the company will have to approach the

bank along with the necessary supporting data. On the basis of estimates submitted by the

company, the bank may decide the amount of assistance that can be extended. While extending

the working capital assistance, the bank may prescribe the margin money requirement. The

margin money stipulation is made by the banks in order to ensure that borrowing company’s own

stake in the business and also to provide the cushion against the possible reduction in the value

of security offered to the bank. The percentage of margin money stipulation may depend upon

the credit standing of the borrowing company, fluctuations in the price of security and the

directives of RBI from time to time. The general principle applicable will be, “more dicey the

nature of security, higher of security, higher will be the margin money stipulations.”

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Form of Assistance:

After deciding the amount of overall assistance to be extended to the company, the bank can

disburse the amount in any of the following forms:

1. Non-Fund Based Lending

2. Fund Based Lending.

Non Fund Based Lending:

In case of Non-Fund Based Lending, the lending bank does not commit any physical outflow of

funds. As such, the funds position of the lending bank remains intact. The Non-Fund Based

Lending can be made by the banks in two forms:

a. Bank Guarantees

b. Letter of Credit

Fund Based Lending:

In case of Non-Fund Based Lending, the lending bank commits the physical outflow of funds.

As such, the funds position of the lending does not affected. The Fund Based Lending can be

made by the banks in following forms:

a. Loan

b. Overdraft

c. Cash Credit

d. Bills Purchased/Discounted

e. Working Capital Term Loans

f. Packing Credit

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Security for Assistance:

The bank may provide the assistance in any of the modes as stated above. But normally no

assistance will be available unless the company offers some security in any of the following

forms.

1) Hypothecation.

2) Pledge

3) Lien

4) Mortgage

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Process of Physical Inventory Maintenance in Apex Auto Ltd

Each unit of Apex auto ltd has its own store department that we can call it as Work-in-

process inventory.

This inventory process is fully computerized and here paper work is very less. Only

maintaining of documents, which were sent by suppliers as like challans etc., are only here to

maintain as paper documents. Otherwise it is fully computerized. Through computers only Store

Department receives Purchase Order and by computer only they send documents of issuing of

materials to manufacturing unit.

For easy to communicate and planning of production activity, Apex Auto Ltd Unit II has

having only one Godown in Procedures involved in receiving and issuing of materials are as

follows:

1) Godown will first get Purchase Order No..

Purchase Order Number:

This PO is comes from Purchase Department. This Purchase Department gives a number

for the each order made by Purchase Department only.

Before placing any order to suppliers they first checks the materials in inventory as to

know about whether materials are available in Inventory or not. If not available in Inventory

then only they will place an order according to the requirement.

In Apex Auto Ltd (Unit II), it is very important to note that: purchase department always

places an order to those materials which have ordered by Customers/buyers of Apex Auto Ltd

(Unit II).

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So, normally it does not have any stocks in its inventory. For every order from customers

they make a fresh Purchase Order for purchasing of materials. It means whatever the materials

are requiring for present orders, those materials are only they kept as stocks in Inventory.

In some cases, materials may be in Godown, which they call it as “Buffer Stock”. If

these old stock is matches the requirements of product which has ordered now by its customers,

then purchase Department will sent a notice to Inventory for issuing of those materials. These

old stock may be in form of Raw Material or in form of finished goods. Apex Auto Ltd (Unit II)

always produces more than its requirements. For example if Telcon has ordered for 20 EX- 70

boom then Apex produces 25 EX – 70 i.e., 20% more than its requirements. So the remaining or

excesses material they call it as “Buffer Stock”.

2) Receiving of Materials

Any materials comes-in or goes-out from the Godown it should be enter in the Gate that

is they call it as “Gate Entry”, which is maintained by security Guard. Guard is not an

employee of an organization. He is a contact-based employee.

When Inventory receives materials it first inspects some samples, so for it, they call up as

“Spot Inspection.” Here they inspect the following points:

a) Is it our supplier only and is this parcel is for us only?

d. Are these received materials according to the Purchase Order? Like

i. Quantity

ii. Date, etc.,

e. Is it having all required Challans or Invoices and also does it approved by authorized

person?

f. Is it having all required documents like Octroi etc.,

g. Is that Challan consisting the correct information of materials?

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After approval of materials by sample inspection, inventory department put these details

in manual book, this documentation is called as “Day Book.” This daybook is consisting of

information like Challan No., P.O. No., Style No., Description of Materials, Supplier’s Name,

transporter’s Name, and Quantity.

After completing of these processes, materials will send to inspection department. In this

inspection department they inspect in-details of materials. After approval by inspection

department, this inventory department makes one document, which is they call it as “Goods

Received Document”.

This Goods Received Document is consisting of GR No., Date, GRN Type (In-store),

Mode of Transport, Challan No., Challan Date, Status, Gate Entry No., Gate Entry Date, Priority

No., all Details of Materials and received quantity and actual quantity also enters there.

3. Issuing of Materials

Merchandising Department will send one card called “Job Card” which it consisting of

all details of materials requires to produce a product. According to that Card Inventory

department should send the materials to manufacturing department.

After receiving of materials by manufacturing department from inventory department

they issue one document about received of materials, quantity, description of materials etc.

Manufacturing Department uses these materials for manufacturing purpose. In manufacturing

process sometimes it may happens like some materials get damages and some are not fully

matches with requirements. Then those materials will be return to inventory.

After utilizing of all these materials by manufacturing department they will send one

document called “Order Completion Report” (OCR). This report consists the information of

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Percentage of Utilized Materials for particular order and percentage of wastage of materials.

This report will send to inventory and also to Merchandising Department.

4. Return Back Materials from Manufacturing Units:

Inventory takes those materials, which are return back from manufacturing units because

of excess or surplus occurs while manufacturing of products. This excess or surplus exists

because of purchase department, they always orders 20% more than its requirement to meet the

requirement of next month. So these materials are kept in Inventory as name it as “Buffer

stock.”

These Buffer Stocks will be utilize when company get the same type of Order. Inventory

issues these materials (Buffer Stock) only when it receives instruction from Merchandising and

purchasing Department.

5. Rejected Materials:

Inspection department make the rejection of materials, when materials are not as per

requirements and not as per the order. These rejected materials are kept in separate section by

Inventory Department.

Inventory department inform to Purchase Department and also notice to Suppliers about

rejection of materials. That is called “Rejection Card.” In this card it involves Name of

Supplier, Description of Materials, Challan No., Challan Date, Gate Entry No. & Date, No. of

Quantity rejected, Reason for rejection etc.,

Some times supplier may issue new materials in place of rejected materials. Or he may

give some compensation for wrong supply and that is after paying of full payment of materials.

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Sections in Inventory:

Inventory is again divided into 5 sections. Each is section handling by only one persons,

with the help of 3 to 4 assistants, who helps in maintaining of materials at specific area. Five

sections are as follows:

Sections in Inventory

D201

All bought out items are been stored here and processed to the manufacturing as when required

D202

All consumables and tools and maintenance accessories are been stored in this section

D203

All raw materials like direct, semi finished goods are stored in this section and processed to the

manufacturing as when required and old stock and rejected items are also stored in this section.

D204

Gas tank and cylinders is stored in this section.

D205

All finished goods are stored in this section

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Purchasing Procedure of Materials

In Apex they purchase materials at from a multiple Suppliers. There is a reason for

purchase materials from multiple suppliers. The reason is if one supplier delays to fulfill the

supply then there must be alternative supplier for it to fulfill the requirement. So there must me

no stock outs in the production process

Apex always purchases at bulk but by schedule wise. In other words they purchase

materials at a time for specific order. They make the agreement of supplying materials only at

once. And they negotiate the price only at once that is before supplying of materials and once

their agreement is over then they provide schedule to supplier to supply the materials at a

specific time and at a specified quantity.

So it reduces the spaces, which occupies in the Godown. So this method is suitable for

this type of industry because of same orders from customers.

WIP Store

Now we come to the WIP Store. As we have already seen that this Apex is having only

one Godown and every unit is having its own Store Departments. As we know that Work In

Process Store means Semi-finished Goods, here goods are not completed yet and not these are in

fully raw materials form.

So in valuation matter it is having slightly different way. And in Apex it is as follows:

Yes, these goods are includes some labour cost, some other costs. So in valuation of WIP they

valuate at Raw Material Price of that goods PLUS incurred cost to produce till now.

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Finished Goods

Valuation of Finished Goods in Apex is at 10% less than Selling Price of those finished

goods. Finished Goods are in the sense these goods should be ready to dispatch.

There is no separate Godown for Finished Goods/Products. Every unit is having it’s own

Finished Goods Godown. In that Godown only they store these Goods. And dispatching of

these products is directly by each unit. They do not consolidate these goods; they dispatch these

finished products directly by each unit.

Apex auto ltd (Unit II) has only one customer that is Telcon. So they directly supply

finished products to its customers. So it is not necessary to have another Godown for Finished

Goods.

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Logistics Inventory Management

There is a department called Logistic Department in Apex Auto Ltd, which is concerning

about selling of goods and maintaining of all documents related to exporting of products and also

taking the permission from banks to sell specific products in specific countries. So Logistic

Department is one of the important front-office Departments, like Marketing Department.

Marketing Department is one, which takes the orders from its customers. And this is

entirely different from Logistic Department. Logistic Department is one, which sells its products

and maintains all documents. But Marketing Department is comes into picture before production

process starts. And Logistic Department comes into picture only after the production process

completes.

Logistic Department is not only taking the approval for selling its products, but also it

will concern for taking loan for its working capital. Banks will provide these working capital

requirements in two senses: one is on Pre-Shipment Loan and another one is Post-Shipment

Loan.

There are so many ways to get loan for working capital requirement. Apex get loan for

Working Capital requirement either through Commercial Papers or through Letter of Credit.

Apex is taking loan for Working Capital Requirements from Axis Bank.

Who can issue the CP:

A company will be eligible to issue the CP provided:

1. the tangible net worth of the company as per latest audited balance sheet is not less than

Rs. 4 Crores.

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Note:

Tangible net worth means share capital plus free reserves duly reduced by intangible

assets like accumulated losses, deferred revenue expenditure etc. Free Reserves include share

premium and debenture redemption reserve but do not include revaluation reserve.

2. Company has been sanctioned working capital limits by banks.

3. Borrowed amount of company is classified as a standard asset by the bank.

Commercial Paper is an unsecured promissory note issued at a discount. The rate of

discount is required to be decided by the issuer and is not regulated.

Before the company issues the CPs it is required to obtain satisfactory credit rating from

an approved credit rating agency. Presently, following credit rating agencies have been

approving by RBI for this purpose.

a. Credit Rating Information Services of India Ltd., (CRISIL)

b. Investment Information and Credit Rating Agency of India Ltd., (ICRA)

c. Credit Analysis and Research Ltd., (CARE)

d. FITCH Rating India (P) Ltd.,

The minimum credit rating required is P-2 of CRISIL. If the rating is given by any other

agency, equivalent minimum rating will be required. The rating so obtained by the company

should be current and should not have fallen due for review.

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Who can invest in CP:

Following persons can invest in the CP

4. Individuals

5. Banks

6. Corporate Bodies incorporated in India

7. Unincorporated Bodies

8. Non-resident Indians

9. Foreign Institutional Investors

Nature of a CP:

h. A CP can be issued for the maturity period of 7 days to one year.

i. A CP has the denomination of Rs. 5 Lakshs and every single investor should invest

minimum Rs. 5 Lakhs in CP.

j. Every issue of CP, including the renewal, will be considered to be the fresh issue.

k. The amount of CP shall be within the overall limit sanctioned by the Board of Directors. It

can be issued a “stand alone” product. Banks will be free to adjust the working capital

limits after considering the CPs issued by the Company.

It will not be out of place to mention here that CP is not treated as deposit as per the provisions

of Section 58-A of the Companies Act, 1956.

Procedure for issuing the CPs:

Every company issuing the CP should appoint a scheduled bank as the Issuing and

Paying Agent (IPA). It will satisfy it-self that company has obtained satisfactory credit rating. It

shall also verify the documents submitted by the issuing company and issue a certificate that the

documents are in order. IPA should also certify that it has valid agreements with the issuing

company.

BSPATIL Page 58


The issuing company shall arrange to place the CPs on private placement basis with the

inventors. The issuing company shall disclose to the potential investor its financial position.

After the deal is confirmed, the issuing company shall issue physical certificates to the investor.

Investors shall be given a copy of IPA certificate to the effect that the issuing company has a

valid agreement with the IPA and documents are in order. Every issue of CP should be reported

to RBI through the IPA within three days from the date of completion of issue.

Apex Auto Ltd (Unit II) has setup in Telcon Premises so as we know earlier that Apex

Unit II is having only one customer that is Telcon so for short distance there is no need of

logistic department in Apex Unit II it is handled by Purchase department incharge is Parmod

Singh.

BSPATIL Page 59



Already we saw about Logistic Inventory Management. Let us see how Apex valuates

the old and rejected stocks in financial terms and also have a look on the inventory ratios.

Valuation method for Old and Rejected Stocks:

Old Stock:

This old stock means excess of materials from specific order. As already viewed in

Physical Inventory Process that, always purchase department purchases 20% more than its

order. So that remained or excess materials are said to be “Buffer Stock”

These Old stock are in the form of Raw Materials then valuate it according to purchasing

of those materials. If these old stock are after Finishing of production process. Then these are

valuating on selling price of same products to the customer.

In easy words it can be said that if materials are Raw, then taking as Purchasing value for

valuation purpose. If materials are Finished Goods then taking Selling Price as a value for

valuation of Old Stock in Godown.

Rejected Stocks:

Again these are divides into three parts. Rejection of Raw Materials i.e., before sending

to Production Process. Rejection of Materials during the Production Process and Rejection of

Materials after the Production Process that is, Rejection of Finished Goods.

Rejection of Raw Materials is valuating on Purchase value of those materials. Rejection

of WIP Materials then valuate as Purchase Value Plus its partly incurred Costs like Labour,

Overhead Costs etc., And for Rejection of Finished Goods valuate at Purchase Value and Fully

incurred Costs as said now.

BSPATIL Page 60


Holding or Ordering Cost

These costs are every important in manufacturing companies to minimize the cost. This

is not applicable to Apex by virtue of its Business activities. Because, let us have a broad view

on statement by following points:

In Apex, they purchase the materials only from multiple supplier.

Because to fulfill the requirements in required time limit.

Apex orders the materials to suppliers only at once and according to the schedule supplier

will supply the materials.

Yes, Depending on Shorter order cycle Apex can hold entire stock well before order starts

and also Apex can have a full stock at a time before starting process of product of that specific

order.

EOQ

EOQ applicability due to the nature of Business as above said is not possible.

Reorder Point:

This is the point is also not having much importance because of nature of Business.

Lead Time

Apex purchases materials from multiple supplier and by on schedule basis to supply

materials. So this is also not applicable in this type of business.

BSPATIL Page 61


Financial Ratios related to Inventory.

Raw material turnover ratio:

Raw material turnover ratio is velocity at which raw material converted into goods ready

for sale. If raw material turnover ratio is high then company is efficiency converting into finished

goods.

Formula: Material consumed / Average raw material

BSPATIL Page 62

Raw Material Turnover Ratio

Year Raw material consumed (Rs) Avg R.M Ratio

2008 576,484,922 53,608,082 10.75

2007 371,223,873 36,137,266 10.27

2006 230,779,236 132,002,490 1.74


Form above graph we come know that raw material turnover ratio is increased rapidly in 2007

from 1.74 in 2006 to 10.27 for 2007. Indicates that company is converting raw material into

finished or semi finished goods very quickly

Holding period of raw material:

It refers to the number of days taken for the production unit to convert raw

material to finish goods.

Formula: 360 /Raw material turnover ratio

BSPATIL Page 63

Ratio

0

2

4

6

8

10

12

2008 2007 2006

Years

Ratio

Holding period of raw material

Year Total Days Ratio Days

2008 360 10.75 33

2007 360 10.27 35

2006 360 1.74 206


As the raw material turnover ratio is increasing form to 10.27 for 2007 it indicates that firm is

taking less days for conversion as compared to 2006. In 2006 conversion period was 206 days

but in decreased to 35 days for 2007. This is shown in above graph.

Before 2007 there was no production process they were converting semi finished goods

into finished products hence to start their own production process they hold the raw material in

2006

Work in Process Turnover ratio:

Work in process turnover ratio is velocity at which W.I.P converted into goods ready for

sale. If W.I.P turnover ratio is high then company is efficiency converting into finished goods.

Formula:

Cost of production

Average W.I.P

W.I.P turnover ratio

BSPATIL Page 64

Raw material holding Period

0

50

100

150

200

250

2008 2007 2006

Years

D A Y S

RHP


Year Cost of production Avg W.I.P Ratio

2008 849,054,442 36,720,702 23.12

2007 555,094,500 15,010,347 36.98

2006 361,110,197 9,755,839 37.01

Form above graph we came to know that Work in process turnover ratio is decreasing from

37.01 in 2006 to 23.12 2008. The ratio was high in 2006 as compared to 2007 and 2008. The

ratio was 37.01. Indicates that company is converting semi finished into finished goods quickly

Holding period of W.I.P:

It refers to the number of days taken for the production unit to convert semi finished

goods into finish goods.

Formula:

360

W.I.P turnover ratio

BSPATIL Page 65

Work in Process Turnover ratio

0

5

10

15

20

25

30

35

40

2008 2007 2006

Years

D A Y S

Ratio


As the work in process turnover ratio is increasing form 9.72. in 2006 To 15.57 for 2008 it

indicates that firm is taking less days for conversion. Which shown in above graph

Finished goods turnover ratio:

Finished goods turnover ratio is velocity at which finished goods converted into for sale.

If finished goods turnover ratio is high then company is efficient.

Formula:

Cost of goods sold

Average finished goods

BSPATIL Page 66

Holding period of W.I.P

Year Total Days Ratio Days

2008 360 23.12 15.57

2007 360 36.98 9.73

2006 360 37.01 9.72

Holding period of W I P

02468

1012141618

2008 2007 2006

Years

D A Y S

Ratio


Form above graph we came know that finished goods turnover ratio is decreasing from 33.01 in

2006 to 27.95 for 2007. Indicates that company is selling goods little slowly as compared to

2006 but it is bit fast as compared to 2008. Where the ratio for that particular period was 32.35

decreased to 11.20 for 2008 it is satisfactory. Which shown in above graph.

Inventory to capital employed:

This ratio indicates the relationship between the total capitals employed and inventories it

shows how much capital utilized to invest in the inventories other than the other assets. The

normal manufacturing firms have low ratio of inventory total capital employed in the

organization.

BSPATIL Page 67

Finished goods turnover ratio

Year cost of goods sold Avg F.G Ratio

2008 849,054,442 26,243,339 32.35

2007 555,094,500 19,858,482 27.95

2006 361,110,197 10,940,008 33.01

Finished Goods Turnover Ratio

25

26

27

28

29

30

31

32

33

34

2008 2007 2006

Years

D A Y S

Ratio


Formula: Inventory / Total capital employed

By observing above graph we can say that the firm investing huge amount in inventories

compared to other assets. It invested 83.54% of its capital in inventory in 2007 where as it

reduced to 65.50% in 2008

Inventory to current asset ratio:

This ratio indicates the relationship between the inventory and current assets. It shows the

percentage of inventory to current assets, which helps the organizations in deciding the current

assets policy which also affect the liquidity position of the organization.

BSPATIL Page 68

Inventory to capital employed

Year Inventory

Total capital

employed Percentage

2008 197,465,069 301,443,215 65.50

2007 121,558,000 145,492,599 83.54

2006 67,994,623 98,333,324 69.14

Inventory to capital employed

0102030405060708090

2008 2007 2006

Years

P E R C E N T A G E

ICE


Formula: Inventory / Current assets

Inventory to current asset ratio

Year Inventory current assets Percentage

2008 197,465,069 331,314,504 59.60

2007 121,558,000 237,687,684 51.14

2006 67,994,623 117,022,625 58.10

The inventory to current assets ratio in the year 2006 was 58.10% and it decreased to 51.14% in

the year 2007 but again it increased to 59.60% in 2008. It shows that the firm investing 59.60%

of its investment is for inventory only.

Inventory to total assets:

This ratio indicates the relationship between the inventory and total assets. The

significance of this ratio is it reflects the portion the inventory as a percentage of the total assets,

BSPATIL Page 69

Inventory to current asset ratio

46

48

50

52

54

56

58

60

62

2008 2007 2006

Years

P E R C E N T A G E

Ratio


which helps the management deciding the utilization remaining resources profitably, since the

inventory will lock up the huge funds and reduces the profitability of the organization

Formula: Inventory / Total assets

Inventory to total assets

Year Inventory Total assets Percentage

2008 197,465,069 990,329,087 19.93

2007 121,558,000 540,916,088 22.47

2006 67,994,623 414,901,234 16.38

During the year 2006 the rate of inventory to total assets was 16.38% it increased to 22.47% in

2007. But again it reduced to 19.93% in 2008. It indicates that firm investing only 19.93% in

inventory out of total assets.

Inventory to working capital:

This ratio indicates the relationship between inventory to working capital and it

also indicates the amount to inventory tied up in the working capital and it also shows the

efficiency of inventory management.

BSPATIL Page 70

Inventory to total assets

0

5

10

15

20

25

2008 2007 2006

Years

P E R C E N T A G E

Ratio


Formula: Inventory

Working capital

In the year the ratio was 146.45% in 2006. It decreased to 83.20% for 2007 but it increased it to

99.05% in 2008. It indicates that firm investing huge amount in inventory

FINDINGS:

1. Raw material turnover ratio is increased rapidly in 2007 from 1.74 in 2006 to 10.27 for

2007.

BSPATIL Page 71

Inventory to working capital

Year Inventory Working capital Percentage

2008 197,465,069 199,345,123 99.05

2007 121,558,000 146,097,210 83.20

2006 67,994,623 46,338,277 146.45

Inventory to working capital

0

20

40

60

80

100

120

140

160

2008 2007 2006Years

P E R C E N T A G E

Ratio


2. As the raw material turnover ratio is increasing form to 10.27 for 2007 it indicates that

firm is taking less days for conversion as compared to 2006.

3.Work in process turnover ratio is decreasing from 37.01 in 2006 to 23.12 2008. The ratio

was high in 2006 as compared to 2007 and 2008.

4.As the work in process turnover ratio is increasing form 9.72. in 2006 To 15.57 for 2008

it indicates that firm is taking less days for conversion

5.Finished goods turnover ratio is decreasing from 33.01 in 2006 to 27.95 for 2007.

Indicates that company is selling goods little slowly as compared to 2006

but it is bit fast as compared to 2008.

6.Company is selling goods little slowly as compared to 2006 but it is bit fast as compared

to 2008. Where the ratio for that particular period was 32.35

7.The inventory to current assets ratio in the year 2007 was 58.10% and it decreased to

51.14% in the year 2008 but again it increased to 59.60% in 2008. It shows that the firm

investing 59.60% of its investment is for inventory only.

8.During the year 2007 the rate of inventory to total assets was 16.38% it icreased to

22.47% in 2008. But again it reduced to 19.93% in 2009. It indicates that firm investing

only 19.93% in inventory out of total assets.

9.In the year the ratio was 146.45% in 2006. It decreased to 83.20% for 2007 but it

increased it to 99.05% in 2008. It indicates that firm investing huge amount in inventory.

BSPATIL Page 72


10.As the finished goods turnover ratio is increasing form 10.87 in 2007 to 12.86 for 2008

it indicates that firm is taking less days for sale. In 2008 conversion period was 12.86 days

but in decreased to 11.20 for 2008 it is satisfactory.

SUGGESTIONS:

a) From the findings it is came to know that in the year 2006 the number of days for

holding Raw material is more, it is not good for the company because it eats

unnecessary investment. To avoid this problem the following points will help.

Purchase Raw Materials at the time when the stock reaches the minimum level.

BSPATIL Page 73


The purchases should not cross the Maximum limit otherwise the stock kept in

stores idle.

Quantity should be ordered as per the demand. We can assume the demand for the

goods from past experience.

We can have more Raw materials which are imported from other countries but carry

reasonable stocks which are available locally.

b) If we purchase less quantity of materials at a time it will reduce the carrying cost

but increases the ordering cost and vise versa. Therefore optimum ordering quantity

is necessary, which minimizes the cost.

c) The company should maintain a safety level and also reordering point so that they

come to know at what time they should order for the supply of material and need

not to suffer from short fall of required material.

CONCLUSION

After the study, we can came to a conclusion that, effectiveness of inventory management should

improve in all the aspects, hence the industry can still strengthen its position by looking into the

following.

BSPATIL Page 74


The inventory should be fast moving so that warehouse cost can be reduced.

The finished goods have to be dispatched in feasible time as soon as manufacturing

is completed.

Optimum order quantity should be maintained, hence cost can be minimized.

Proper inventory control techniques are employed by the inventory control

organization within the framework of one of the basic models like ABC, HML and

VED etc.

BIBIIOGRAPHY

BOOKS

Financial Management : I.M.Panday

BSPATIL Page 75


Production Management : K. Ashwatappa

WEBSITES

www.apexautoltd.com

www.google.com

BSPATIL Page 76

http://www.apexautoltd.com/


BSPATIL Page 77

97631664 inventory-management-project-report

Business

inventory management

inventory managementstatement

inventory level

impact of inventory

studyinventory management

probleminventory management

monthly inventory statements4

stated management problem