REPORT ON

GOLD PLUS TOUGHENED GLASS LTD.

&

GOLD PLUS GLASSES INDIA LTD.

Tenure: - 28.12.2010 to 28.01.2011

Project Topic: “Optimization of inventory and fixing up of minimum

stock level of common items in both the stores of GPG and GPT”

UNDER THE GUIDANCE OF UNDER THE MENTORSHIP OF

Mr. Prem Dutt Mr. D.S. Choudhary

(GM-Technical) (Plant Head)

SUBMITTED BY:

Sachin Kumar
(Management Trainee)
 ACKNOWLEDGEMENTS

It is my immense pleasure to present the project report on “Optimization of inventory

and to fix up minimum stock level of common items in both the stores of GPG and
GPT”.

Before I get into thick of things, I would like to add a few heartfelt words for people
who were part of this project in many respects.

I take this opportunity to acknowledge the initiatives of Mr. Prem Dutt (GM
Technical) whose guidance helped me immensely to successfully complete my
project. He was a great source of inspiration and motivation.

I also like to express my gratitude to Mr. D.S.Choudhary (Plant Head). Without his
support and motivation this work cannot come to a end.

I would like to thanks Mr. Tarun Riyal (Store Incharge, GPG) and Mr. Yogendra
Tyagi (Store Incharge Assistant) and every other persons who has helped me in
providing me the necessary data required to complete my project.
About the Sonipat plant

The Sonipat plant consist of two units i.e Gold Plus Glasses India Ltd. which was
established in 1996 & spread in an area of around 1 acre & gold plus toughened glass
ltd. which was setup in 2001 spread in an area of around 2 acre.The total work force
of both units is more than 400 employes plant processed various types of flat clear
glass into toughened, laminated & insulating glass in various segment such as
automotive & architectural as per customer requirement.

In the starting one week of my training in the plant I had gone through various
specifications of the machines in both the plant and observed the working of different
machines. The specifications of different machines are mentioned in the report.

After one week my guide Mr. Prem Dutt assigned me the project of optimization of
inventory. During the period of my training in completing the project I
communicated with various people from stores as well as maintenance department to
collect the data required for the completion of my project. In the whole process I
learned about various number of spare parts used in the machines and also about the
number of common parts and their annual consumption pattern. The detail
information is given in the later part of the report.
SPECIFICATIONS OF DIFFERENT MACHINES EMPLOYED IN THE
PLANT:

1. CNC MACHINE (GPT)

S.NO SPECIFICATIONS
1 TYPE GFB – 37/26
2 MANUFACTURER PETER LISEC AUSTRIA
3 WEIGHT 3850 KG
4 MAXIMUM GLASS SHEET SIZE 3700 X 2600 MM
5 MINIMUM GLASS CUTTING SIZE 50 X 50 MM
6 ACCURACY (+/-) 0.4 MM
7 GLASS THICKNESS 2.5 to 19 MM
8 MAXIMUM LOAD ON CUTTING TABLE 50 KG/M2
9 VOLTAGE 415 V
10 POWER LOAD 8.1 KVA
11 AIR OPERATING PRESSURE 6 TO 8 BAR

SETTING FOR GLASS CUTTING

S.NO GLASS WHEEL CUTTING TRIM CUT

THICKNESS ANGLE AIR
PRESSURE
1 2.5MM TO 4MM 135° 0.5 TO 1 BAR 5MM TO 15MM
2 5MM TO 8MM 145° 1 TO 3 BAR 10MM TO 20MM
3 10MM TO 12MM 155° 2.5 TO 3.5 BAR 20MM TO 25MM
4 15MM TO 19MM 165° 3 TO 4 BAR 30MM TO 40MM
Thickness of different Glasses that feed in CNC Machine is: -

1. 2.5 mm

2. 3 mm

3. 3.5 mm

4. 5 mm

5. 6 mm

6. 8 mm

7. 10 mm

8. 12 mm

2. SCIHIATTI – 004

S.NO SPECIFICATIONS
1 TYPE STRAIGHT GRINDING
MACHINE
2 MODEL R1/6M
3 MANUFACTURER SCHIATTI ANGELO, ITALY

4 WEIGHT 2105 KG
5 TOTAL MACHINE LENGTH 7053 MM
6 WORKABLE GLASS THICKNESS 3 TO 20 MM
7 MIN. WORKING DIMENSIONS 150 X 500 MM
8 MAXIMUM SIZE OF GLASS 3000 X 3000 MM
9 POWER LOAD 10.7 KW
10 POWER SUPPLY 415 V
11 AIR PRESSURE 6 TO 8 BAR
12 TANK CAPACITY 190 LTR
13 ABRASSIVE USED D - 120
3. Z – BAVELLONI GRINDING MACHINE

S.NO SPECIFICATIONS

1 TYPE VERTICAL STRAIGHT LINE

EDGING MACINE

2 MODEL PR/88

3 MANUFACTURER Z-BAVELLONI, ITALY

4 WEIGHT 3550 KG

5 TOTAL MACHINE LENGTH 7.1 M

6 WORKABLE GLASS THICKNESS 3 TO 31 MM

7 MINIMUM WORKING DIMENSION MIN. 50 MM HEIGHT

8 WORKING SPEED 0 TO 5 M/MIN

9 POWER LOAD 16.7 KW

10 POWER SUPPLY 415 V

11 MAX. WEIGHT ON CONVEYOR 200 KG/M

12 AIR PRESSURE 6 TO 8 BAR

CONVEYOR SPEEDS

S.NO GLASS TYPE OF EDGE WORK SPEED (M/MIN)

THICKNESS

1 5 TO 6 MM ROUGH & POLISH 2.8 & 2.0

GRINDING RESPCT.

2 8 TO 10 MM POLISH GRONDING 1.2

3 12 MM POLISH GRINDING 1.0 TO 1.2

4 15 TO 19 MM POLISH GRINDING 0.8 TO 1.0

WHEEL PRESSURE SETTING

S.NO EDGE WORK WHEEL POSITION PRESSURE

1 FLAT POLISH POSITION (7 & 8) 6 BAR

2 WITH ARRIES POSITION (4 & 6) 3 BAR

4. VERTICAL WASHING MACHINE

S.NO SPECIFICATIONS

1 MODEL K50KZ18Q

2 MANUFACTURER KEDA, CHINA

3 THICKNESS OF WASHING MACHINE 3 TO 12 MM

4 MINIMUM GLASS SIZE 540 X 200 MM

5 MAXIMUM GLASS SIZE 2500 X 1800 MM

6 WORKING SPEED 2 TO 10 M/MIN

7 POWER 2.7 KW

8 POWER SUPPLY 415 V

5. HORIZONTAL WASHING MACHINE

S.NO SPECIFICATIONS

1 TYPE QXJ-25B

2 MANUFACTURER SHENZEN HANDONG, CHINA

3 DIMENSIONS (L*W*H) (5400 X 3510 X 1450) MM

4 WEIGHT 4360 KG

5 TOTAL POWER 38.01 KW

6 POWER SUPPLY 3-f 415 V

7 AIR SOURCE 1.88 M2/MM

8 MINIMUM GLASS SIZE 300 MM X 300 MM

9 MAXIMUM GLAS WIDTH 2500 MM

10 GLASS THICKNESS 3 – 45 M/MIN

11 SPEED 0.6 – 5M/MIN

12 RUBBER ROLLER DIAMETER 75 MM

13 BRUSH DIAMETER 160

6. HTF MACHINE (GPT)

S.NO SPECIFICATIONS

1 TYPE HORIZONTAL TEMPERING

2 MODEL 2436 BCTA-10-R

3 MANUFACTURER TAM GLASS, FINLAND

4 WORKABLE GASS THICKNESS 3 TO 19 MM

5 MIN. WORKING DIMENSION 250 X 250 MM

6 MAX. SIZE OF GLASS 3600 X 2400 MM

7 POWER LOAD FOR HEATING 546 KW

8 COMPRESSOR LOAD 160 KW

9 POWER SUPPLY 415 V

10 BLOWER POWER LOAD 400 KW, 18.5 KW

11 AIR PRESSURE 6 TO 8 BAR

7. CNC MACHINE (GPG)

S.NO SPECIFICATIONS

1 MODEL GENIUS 37 CI

2 MANUFACTURER INTERMAC, ITALY

3 SERIAL NO. A22371

4 WEIGHT 270 KG

5 POWER SUPPLY VOLTAGE 440 V

6 RATED CURRENT 11 A

7 PHASES 3-f

8 POWER 6.5 KW
ELECTRICAL SPECIFICATIONS OF GPT AND GPG:

GPT:

TRANSFORMER- 2000 KW

DG1 – 750 KVA

DG2 – 380 KVA

GPG:

TRANSFORMER – 1500 KW, 1000 KW

DG1 – 1500 KVA

DG2 – 250 KVA

POWER SUPPLY FLOWCHART

HVPN (11 KV)

GO SWITCH

ENERGY METER

STEP DOWN T/F(440

V) GENERATOR

LT PANEL
ACB

MACHINES
OBJECTIVES OF THE PROJECT:

1. To optimize the inventory in both GPT and GPG plant in order to minimize
the lock up of finance in stock.

2. To fix minimum stock level of common inventory in both the plant GPT and
GPG.

INTRODUCTION:

Both GPG and GPT plant has separate stores. The working of both the stores are
independent to each other. But since there are many process in both the plants which
are common to each other. Therefore, both the stores have many common items. The
consumption of different common items is different. Some items are consumed much
as compared to other items. The consumption of items depends upon their usage. So,
the main objective of this project is to find those common items and to fix up the
minimum stock level of these items.

INVENTORY MANAGEMENT:

Inventory management is primarily about specifying the size and placement of

stocked goods. Inventory management is required at different locations within a
facility or within multiple locations of a supply network to protect the regular and
planned course of production against the random disturbance of running out of
materials or goods.

The scope of inventory management also concerns the fine lines between
replenishment lead time, carrying costs of inventory, asset management, inventory
forecasting, inventory valuation, inventory visibility, future inventory price
forecasting, physical inventory, available physical space for inventory, quality
management, replenishment, returns and defective goods and demand forecasting.
Balancing these competing requirements leads to optimal inventory levels, which is
an on-going process as the business needs shift and react to the wider environment.
Inventory management involves a retailer seeking to acquire and maintain a proper
merchandise assortment while ordering, shipping, handling, and related costs are kept
in check.

Systems and processes that identify inventory requirements, set targets, provide
replenishment techniques and report actual and projected inventory status. Handles
all functions related to the tracking and management of material. This would include
the monitoring of material moved into and out of stockroom locations and the
reconciling of the inventory balances. Also may include ABC analysis, lot tracking,
cycle counting support etc.

Management of the inventories, with the primary objective of determining/controlling

stock levels within the physical distribution function to balance the need for product
availability against the need for minimizing stock holding and handling costs

STORE MANAGEMENT:

1. Stock Policy

• Establish a stock policy

• Make the stock policy clearly known to all staff concerned

• Establish specific written instructions for compliance

• Specify in the policy:

1.The types of items that will be stocked

2.The factors that determine the stock levels
3.The inventory system to be adopted
2.Stock Records

• Maintain a complete and proper record of the items in stock with the
following particulars

1.Reference and description of each item

2.Quantity and location in the store
3.Expiration date (if any) of each item
4.Date and quantity of each transaction
5.Current stock balance for all items
• Properly design and complete store vouchers to capture all necessary details
of a transaction

• Use sequential numbering control to facilitate checking of store vouchers

• Properly document and approve cancelled or amended transactions

• Securely hold all stock records

• Where a computer system is used, restrict the access to it and control it

properly. Implement effective information security protocols.

3. Control and Supervision

• Maintain adequate division of labour between:

1.Issue of goods
2.Receipt of goods
3.Updating of store inventory record
4.Updating of accounting records
• Clearly define the duties of an officer in charge of a store and make them
known to the staff concerned

• Establish a procedure for handing over the management or supervision of a

store
4. Receipt of Stores

• Put in place adequate physical safeguards in the goods receipt procedure

• Properly document and account for each goods receipt voucher

• Establish policies and procedures for handling exceptional matters of goods

receipt

• Establish written procedures for lodging claims for supply and delivery
problems

5. Issue of Stores

• Properly document and account for all delivery vouchers

• Issue store items on a "first in - first out" basis

• Properly control the issue of goods eg. check the voucher authorizations
against a record of specimen authorized signatures

6. Stock Checks

• Conduct regular and surprise stock checks

• Establish policies and control procedures to cater for stock discrepancies

• Set appropriate limits of authority for writing off any loss or deficiency of
stores

7. Disposal of Stores

• Clearly define the items which are to be discarded

 • Establish proper procedures for disposing of these items

DATA COLLECTION:

1. The collection of data is done for the financial year 01.04.09 to 31.03.10.

2. A list has been prepared of the items used in both the plant GPG and GPT
having total number of items with information like opening quantity, receipt
quantity, issue quantity and balance quantity for one complete financial year.

3. Then two more lists are prepared of the items having minimum stock level of
each item and annual consumption in a financial year.

4. By observing the data of both the list of GPG and GPT plant, a list is prepared
of common items used in both the plants and having written monthly annual
consumption and the minimum stock level, these items should have.

5. The collection of data is both primary and secondary.

Advantages of an Inventory Management System

• Supply and Demand: Having an adequate supply of a particular product

to meet customer demand is crucial to both sales increases and customer
service. If a customer comes to a business to purchase a product and it is
out of stock, the sale is lost forever and the customer will probably go to a
competitor to find what they need. A good inventory management system,
whether computerized or manual, will identify sales trends and prepare for
customer needs.

• Streamline Operations: Manufacturing facilities should always maintain

proper inventory of the supplies necessary to produce their products. If
one component is missing from the inventory, the whole production
process is interrupted. Streamlined operations are an important benefit of
an effective inventory management system.
• Lead Time Adjustments: Inventory management systems are important
for determining when to order certain items, especially for products with
varying lead times. Some products take longer to receive from the
manufacturer than others, and it’s important to have an inventory
management system that accounts for lead-time. If for example, a grocery
store was going to have a sale on hotdogs, relish and mustard, but the
hotdogs took longer than three days to receive while the condiments took
five days, the inventory management system would need to ensure that all
items were in stock in time for the sale.

• Reduce Liabilities: Another significant advantage to an inventory

management system is it reduces the liabilities and loss created by
overstock. Similar to monitoring supply and demand, a good inventory
management system will notice declines in sales or identify one-time
occurrences to prevent over-ordering certain products. For instance, if a
clothing store was having a sale on a certain style of jeans, it may order
additional stock to meet customer demands. The inventory management
system should take the sale into account before ordering more of the jeans
based on the spike in sales. Otherwise, they store may have to offer even
deeper discounts to get rid of the excess inventory.

• Reduces the lock up of finance: If inventory is managed properly and

proper data is maintained of minimum level of stock of the items
consumed in larger amount then then the finance involved in these items
can be reduced.
CONCLUSION:

After completion of the project we have got the list of those common items (spare
parts), which are used, maximum in both the stores. So, we have determined a
minimum level of stock of these items by calculating the average monthly
consumption of these items. So, we can optimize the quantity of these items so that
finance involved in buying these items should remain minimum and the items do not
go out of stock.

Also, by observing the data having minimum stock and annual consumption of items
from the individual list of the minimum stock of items of both the stores we can
revised the minimum stock of items of necessary by observing the consumption of
these items in one complete financial year.