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MPM Inventory Management

PART-A

GENERAL INTRODUCTION

There are four important components for running an industrial organization i.e.,
Men, machine, material and money. All these four components have to be employed in
an industry in order to make the manufacturing process to extract the finished products
and marketing it properly to get sales realization with profit.

Profit making is an important goal or an object of any industrial organization. To


attain the maximum profitability utilizing the above set Four M’s to the optimum level.
Money is used for procurement of the material which is required for the production.
During the time of procurement the requirement of the proper material has to be
identified and required quality and quality of material has to be decided in advance.

This is nothing but a process of material procurement planning. The very purpose
of planning of procurement of material is to purchase the good quality material for a most
competitive lowest price. This will help the organization to undertake manufacturing
process most effectively with minimum or nil wastage.

Many times in an industry organization’s improper planning in material


procurement leads to filing up material stock in the form of raw-materials; semi-finished
goods ( W-I-P) unsold finished goods.

The aim of such stock is called inventory.

Any unwanted stock leads to debt capital which cannot be appreciated as good
financial management. Hence, material and money are playing a vital role in the efficient
financial management.

This project is select to have detailed study about the “Financial Planning and
forecasting” which is the one of the important activity in any industrial organization to
reach the organization goal with out much effort. Because, inventory management has to
be definitely considered for the increase of profitability and reduce the unwanted
working capital investment in the process of manufacturing.
MPM Inventory Management

INDUSTRIAL PROFILE
The invention of paper
Written communication has been the center of civilization for centuries. Most of
our important records are on paper. Although written has been around for a long time,
paper hasn’t. infact, putting thoughts down in written form wasn’t easy or partial. Earlier
people discovered that they could make simple drawing on the walls of caves which was
a great place for recording thoughts, but wasn’t portable.
Imagine spending hours scratching a massage into a heavy clay table and then
having to transport it, that’s exactly what the Sumerians did around 4000 BC. Although
this form of written communication was not portable, is still wasn’t practical because of
its weight.
For centuries people tried to discover better surface on which to records their
thoughts. Almost everything imaginable was tried. Wood, stone, ceramics, cloth, bark,
mettle, silk, bamboo, and tree leaves were all used as a writing surface at one time or
another.
The word ‘paper’ is derive from the word “papyrus” which is plant found in
Egypt along the lower Nile River. About 5000 years ago, Egyptians created “sheets” of
papyrus by harvesting, peeling and slicing the plant into strips. The strips were then
layered, pounded together and smoothened to make a flat, uniform sheet.
The person credited with inventing paper is Chinese man named Ts’ai Lun. He
took the inner bark of a mulberry tree and bamboo fibers, mixed them with water, and
pounded them with a wooden tool. He then poured this mixer on to a flat piece of
coarsely woven cloth and the water drain though, leaving only the fibers on the cloth.
By the tenth century Arabians were substituting lines fiber for wood and bamboo,
creating a finer sheet of paper. Although paper was of fairly high quality now, the only
way to reproduce written work was by hand, painstaking process.
By 12th century paper making reached Europe. In 1448, Johannes Guttenberg, a
Germen, was credited with inventing printing press. ( it is believed that movable type was
actually invented hundreds of years earlier in Asia ). Book and other important
MPM Inventory Management
documents could now be reproduced quickly. This method of printing in large quantities
led to a rapid increase in the demand for paper.

Some of the important development in recent decades is as follows:

1. Multi-stage bleaching of Kraft-paper, lending to availability of fully bleached


Kraft- pulp.
2. Use of chloride-di-oxide for pulp for pulp bleaching permitting higher rightness
with the retention of strength.
3. Coating of paper, while passing through the paper machine dryer section. Greatly
expanding use of coated paper for printing.
4. Use of soluble bases for sulfite pulping permitting pulping of more species wood
by the sulfite process.
5. Bleaching of high yield pulp, ground-wood and semi-chemicals.
6. Wet strength paper use of synthetic resins for economic production of wide
variety of paper that are strong when wet.
7. Multi-stage sulfites pulping permitting greater variety of pulp properties.
8. Continues cooking of Kraft and semi-chemicals pulp making is possible,
reduction in capital and operating cost.
9. High yields pulping: combined chemical and mechanical action to produce pulp
from wood in high yield.

The geographical spread of the industry is given in the following table:

State No of Mills
Andhra Pradesh 39
Assam 2
Bihar 7
Chathisghad 9
Gujarat 91
Haryana 17
Himachal Pradesh 7
Jammu and Kashmir 1
Jharkhand 2
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Karnataka 19
Kerala 13
Madhya Pradesh 27
Maharashtra 90
Nagaland 1
Orissa 6
Pond Cheri 7
Punjab 73
Rajasthan 70
Tamil Nadu 34
Uttar Pradesh 94
Uttaranchal 16
West Bengal 26
Total 594

Indian paper industrial scenario:

The paper industry is cyclical in nature: its demand is linked to the level of
economic activity and the supply is influenced by domestic production and as well as
international trade in pulp and paper.
USA ( over 30% ), Western Europe (around 20%), and Japan (12-15%) account
for a major portion of the demand. Global demands add stagnated in 1990-93 at around
250MN TPA with showing down of economic growth. Per capital consumption actually
dropped 3-5% and with dropping demand capacities closed down. The recovery started
in 1993-94 with improvement economic outlook. In 1994-95 international pulp and paper
prices kept rising on the back of growing demand.
India’s per capital consumption is very low at 3 kg against a world average of
over 45 kgs, domestic industry has nearly 600 mills with an aggregate capacity of 3.8
MN tons per annum. Out of 600 mills, 30 are large wood/bamboo based mills, 80 are
agro based and rest are waste paper based. The effective capacity is about 2.6 million
tones as a lot of mills are sick. In the new s print segment total capacity is
around0.4million TPA (MTPA), of this 73% is dominated by four major players in the
public sector while the rest of the capacity is shared by 14 players.

Structure of paper industry;


MPM Inventory Management
The industry can be classified on the basis of size, the type of raw materials
consumed and the end product manufactured.
The Indian paper industry comprises of nearly 600 mills with a total capacity of
around 3.8 M TPA. More than 200 mills have capacities of less then 20000 TPA. There
are 12 companies with a capacity of 50,000 TPA and only 2 with 1,00,000 TPA and
above.
Based on the raw material used, the mills can be classified as wood-based ( hard
wood or bamboo ), agro residue based ( baggase and rice / wheat straw ) and news paper
based ( imported waste paper and pulp ).

Structure of paper industry based on end product produced.

Paper and paper board News


print

Structure of paper industry based on Raw materials required for making paper.

Wood Agro based Secondary Waste


Paper
MPM Inventory Management
(Hard Wood & Raw-materials & Imported
pulp
Bamboo) (Baggase, Straive Glasses,
Jute waste, Cotton Liners
& Industrial waste)

Future prospectus of paper industry:

Strong demand from packaging segment will drive demand growth for industrial
paper. Establishment of new business area such as telecom and power will lead to
increasing literacy levels, thus improving low per capital consumption of paper (3.2 kgs
p.a). Besides rapid growth in population, enhanced literacy levels, growing quality
consciousness and changing consumer preferences will drive paper demand.

In view high capital costs, expansion of existing units and revivals of sick units
remain the practical option for capacity addition. Also, paper mills in India have to look
for ways to cut down costs to compete with imports.

International paper prices are not expected to prices are not expected to price
substantially over the short medium term. Domestic paper companies will thus continue
to reel under the pressure of reduced margins. However, a depreciating rupee will
marginally protect domestic companies from imports. Due to increased supply, some of
the companies have put their expansion plans on hold or have reduced their investment
opting for lesser capacity expansions.

HISTORICAL PAPER INDUSTRY DEVELOPMENT IN INDIA

Indian paper industry is classified broadly into two categories into two categories
paper and paper bonds then newsprint. The paper and paperboard segment constitutes of
cultural paper, industrial paper and special paper.
MPM Inventory Management
Paper industry in India has a long history with the first mill being commissioned
in 1832. The initial development and growth of paper industry till the early nineteenth
century was affected by the shortage of wood (soft wood) in the country. But in 1914, in
development of a process based on bamboo lead rapid growth of domestic industry. By
the end of sixties, the capacity for paper production lagged, demand and imports
increased to approximately 10% of the domestic demand. Most of the domestic
production was concentrated in the hands of a few large mills. By the late sixties, bamboo
as an input to paper industry came under short supply. Taking this into account, the
government of India started encouraging small units based on an agro residue and waste
paper in the seventies. Fiscal incentives were also offered. This lead to spurt in the
number of mills with small capacities.
But from the late eighties industry started facing an oversupply situation lower
price realization and plant closures. The downtrend continued till 1992, when demand
supply situation improved.
From 1993, step with the easing of the worldwide recession in the industry,
investments stated increasing. A booming capital market also helped in raising money for
new capacities. The industry was in a jolly mood up to 1996.
The increase in supply coupled with a worldwide recession has pushed the Indian
paper industry back into down trend. The global cycle was further affected by the Asian
crises, which has reduced demand considerably.
Since 1990 the paper industry in India, is following global cycle with periods of
over capacity leading to drop in paper prices, lower capacity utilization and slow down
in investments/capacity addition, followed by closure of mill, decreased in demand
supply gap and then back full circle to an increase in paper prices.

BASIC PROBLEMS FACED BY THE NEWSPRINT IN INDIA

The economic liberalization policies initiated by the Narasimha Rao committee


government in 1991 have been carried through vigor in successive years. As a result
MPM Inventory Management
industry is on the road to globalization and its getting even more inter wined with the
overseas market.
The sharp rise is pricing during 1973-74 created a paper crisis in the county.

HIGH COST OF PRODUCTION


1. The international price of capital equipment needed by the news print industry has
been souring. Over cost too have been rising quite fast.
2. Power and coal both supplied by the public sector units have risen by 400% in the
last decade.
3. Similarly chemical materials have also risen by similar percentage; royalties on
bamboo and hard wood have been increased by 100% to 700% in the last 6 years
in some states.
4. The acute shortage of local timber and heavy excise duties has burdened the
newsprint industry, which has been struggling all along out and above all these
problems there is services power cut, especially in south India.
Future Prospects of paper industry:

• Establishment of new business area such as telecom and power will lead to
increasing literacy levels, thus improving the low per capita consumption of paper
(3.2 KGS per annum). Besides rapid growth in population, enhanced literacy
levels, growing quality consciousness and changing consumer preferences will
drive paper demand.
• In view of the high capital costs, expansion of existing units and revival of sick
units remain the practical option for capacity additions. Also, paper mills in India
have to look for ways to cut down costs to compete with imports.
• International paper prices are not expected to rise substantially over the short-
medium term. Domestic paper companies will thus continue to reel under the
pressure of reduced margins. However, a depreciating rupee will marginally
protect domestic companies from imports. Due to increased supply, some of the
companies have put their expansion plans on hold or have reduced their
investment opting for lesser capacity expansions.
MPM Inventory Management

COMPANY PROFILE

Background and inception of the company


The MPM situated on the bank of river Bhadra at Bjadravathi, Shimoga Dist.,
Karnataka state, was incorporated in the year 1936 as a joint sector company. The
foundation stone was laid by the then Maharaja of Mysore Sri. Krishanarajendra
Wodeyar. It was started with a small capacity of Rs.2.5 million. Since inception, the
MPM never looked back. It went from one threshold of progress to another expanding
its annual capacity to 8000 MT in 1952, then to 18000 MT in 1964 and to 24000 MT in
1972.
In 1976 the company ventured a major expansion project by installing new
machinery to produce 75000 MT of news print per annum and increasing the capacity
from 24000 MT to 30000 MT per annum of writing and printing varieties of paper. The
project was completed during 1981. In 1983, a sugar mill of 2500 TCD was
commissioned and thus MPM become the first largest, single location integrated plant in
the country manufacturing news, writing and printing paper and sugar at a single
location. The integration of sugar mill with paper mill is with the idea of utilizing the by-
products of sugar mill i.e., sugar cane baggase for paper production and avoid
dependence of forest based raw materials and avoid deforestation. With the
commissioning of newsprint project, the company was able to help the country to reduce
imports substantially.

Growth/ history of MPM in chronological order:

Year Activity

1936 Incorporated as a public sector company

1937 Commercial production started with 4000T per annum

1952 First expansion: production increased to 8000T per annum


MPM Inventory Management
1964 Second Expansion: production increased to 18000T per annum

1972 Modernization: production increased to 24000T per annum

1976 Major expansion to manufacture 75000T per annum news print and to increase
writing & printing paper production from 24000T per annum to 30000T
per annum.

1981 commercial production of newsprint started with self power generation of 25MW

1983 commissioning of 2500 tons sugar mill

1993 conversion of stoker fired boilers into SR boilers

1994 refitting of chemical recovery boilers

1998 commencing of 90T/Hr SR boiler along with 3rd extraction cum back pressure
turbo generator (TG) of 16MW capacity, thus increasing the self power
generation capacity to 41MW

2002 expansion of effluent treatment plant with increased aeration capacity and
introduction of post Aeration treatment

2004 Retrofitting of SR evaporators. ISO14001 certificate (for pollution control) and


also ISO9001 for quality of product.

VISION MISSION AND ORGANIZATION STRUCTURE OF MPM:

VISION
“Mysore papers mill committed to deliver products and service
to satisfy the needs of customer.”
♦ To make continuous effort to improve quality by continuous training
♦ To actively involve people to contribute toward high productivity through
teamwork and innovation.
♦ To consciously work toward conversion of resources and minimization of
wastes of all forms.
MPM Inventory Management
MISION
♦ Creating a vibrant work culture
♦ Customer Satisfaction
♦ Consistent quality
♦ Competitive price.
♦ Enhancing productivity

A GLANCE OF THE ORGANIZATION:

• NAME OF THE COMPANY : MYSORE PAPER MILL LTD

• TYPE OF THE COMPANY : PUBLIC SECTOR COMPANY

• LOCATION : BHADRAVATHI(T),

SHIMOGA(D), KARNATAKA

• ESTABLISHMENT : 20TH MAY 1936

• COMPANY Reg., No. : 173

• PRODUCTS : PAPER AND SUGAR(subsidiary)

• RAW MATERIALS : BAMBOO, EUCA, ACACIA, PINE


AND BAGASSE

• CAPACITY : 30000T WRITING PRINTING &

SPECIALIT PAPER 75000T


NEWSPRINT 2500T
SUGARCANE CRUSHING

• CORPORATE OFFICE : BANGLORE

• REGIONAL OFFICE : DELHI, MADRAS, KOLKATTA &


MPM Inventory Management
MUMBAI

QUALITY POLICY

MPM shall be reputed, profitable and growth oriented company


employing skills that take pride in satisfying customer needs with superior
products and services.

AREA OF OPERATION

The regional office is situated at 16/5, Ali Asker Road, Bangalore. The
branches offices are situated at New Delhi, Mumbai, Kolkata and Chennai.

COMPETITOR:

Ballarpur Industries Ltd., Maharashtra.

a) Year of starting 1997

b) Annual Capacity – 1.10.00 tones per year

c) Grades of paper

Writing, printing, packing and industrial paper

Rama Newsprint and papers Ltd., Gujarat

a) Year of starting – 1996

b) Annual Capacity – 132-00 Tones per year

c) Grade of paper-- Newsprint

Tamil Nadu Newsprint and paper Ltd., Tamil Nadu


MPM Inventory Management
a) Year of starting – 1984

b) Annual Capacity – 180-00 Tonnes per year

c) Grades of paper -- Newsprint, printing and writing

Andrapradesh paper mills Ltd., Andra Pradesh

a) Year of starting 1966

b) Annual capacity 98.5-00 tones per year

c) Grades of Paper--Base paper, wedding and greeting cards

The West coast paper mills Ltd., Dandeli

a) Year of starting – 1958

b) Annual capacity – 157.750.00 metric tones per year

c) Grades of paper--Writing and printing board including MICR and


Copier

d) It is a private company.

CUSTOMER OF THE MPM


M.P.M. News print is used for printing Newspaper in all languages in India. A
few of important customer are as follows,

English News Paper


• Times of India
• New Indian Express
• Deccan herald
• The Hindu
• The State man
• The Tribhuvan
MPM Inventory Management
Kannada News Paper
• Prajawani
• Samyuktha Karnataka
• Udayavani
• Kannada Prabha

Tamil Paper
• Dina malar
• Dinakaran

Telugu News Paper


• Enadu
• Vartha
• Andra Bhumi

Marathi News Paper


• Sakal
• Maharastra times
• Samachar

APPLICATION OF MCKENSY’S 7S MODEL

The 7-S framework was developedStructure


by the consultant at the Mckensy’s Company,
a very well known management consistency firm in USA, towards the end of 1970’s to
diagnose the cause of organization problem and to formulate programs for improvement
the 7-S framework.
Strategy Systems

Shared
values

Skills Style

Staff
MPM Inventory Management

SKILLS:
In Mysore paper mills Ltd employees are to be recruited on the basis of their
Qualifications. Training facilities be provided to be both employees both internal and
external. There are 3 types of labours based on their skills they are

1) skilled labours
2) semi-skilled labours
3) un-skilled labours
STYLE:

The management believes in an open organization. In Mysore paper mills Ltd.


They do not involve employees for taking any decision. The management will be taking
the decision itself may be in any area like production decision, marketing decision.
Management itself takes all finance decisions.

STRATEGY:
The Mysore paper mill limited started on 1st April 1937 in the remote village of
Bhadravathi. There is no perfect mission statement in the MPM but the main aim of the
company will be producing good quality of paper and sugar to the public as well as
providing more number of employment and increase the standard of living of the people.
The Mysore paper mill company’s business philosophy is based of three core
values; they are operational excellence, Customer’s focus and product leadership.
The business strategy emphasizes the following
1. Increase their market shares.
2. Reduced cost of production.
MPM Inventory Management
3. Increase company performance.
4. Produce always quality product.
5. To meet social responsibilities.
6. Provide employment opportunity to the people of the area.
7. Meet the national and regional demand of paper and paperboard.
8. Reduce the import of news print from the foreign market.
9. Reduce the import of news print from the foreign market.
10. To manufacture and deal in all kinds of sugar and sugar products
11. To manufacture and deal in all kinds of sugar and sugar products
12. To cultivate and raise grass, timber, wood eucalypt.
13. To grow niligiri plant within the premises of the company. Which
Provide raw materials for the company at low cost.

14. Recycle all the wastage products.

SYSTEMS:

The management believes in the utilization of cutting edge technology of


deliver world class products and services. The company has made huge
investments in technological resources to ensure that products are superior and the
service delivery in terms of these products offering standard.

The system of the Mysore paper mills limited company clearly shows the
formal processes and procedures used to manage the organization, including the
control system, performance management measurement and reward systems,
planning budgeting and information system they follow the bottom to top
approach in decision making. That means first they collect the opinion of trade
unions based on that the top management take the decision which is better for
company.

STAFF:
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Staff requirement is designed to ensure that those on board have the primary
focus as customer service with a high level of product and process knowledge and
operation excellence. Induction and training program are designed to conduct for
all employees at regular basis to ensure that these levels are continually enhanced
feed back for continuous improvement in solicited from all understood. Being a
dynamic organization susceptible and the changes are well understood.

Being a dynamic organization to frequent change in policy so as to suit


business needs that require to be a learning organization fulfilled by the systems
and processes which document all changes and feedback received. Development
programmes are conducted by MPM every year only for the persons who are in
the management cadder. Which helps them to improve their skills and
knowledges?

WORK FLOW MODEL:


MPM Inventory Management
1. Purchase Orders:

At the first stage the company receives purchase order from its agents. They are
mentioning the product grade, quality, quantity etc.

2. Release Raw Material to Pulp Mill:

The purchase department releases the raw materials to the pulp mill

3. Pulping Process:

In this pulping process the raw material pulping made in pulper with water. It will
undergo cleaning of pulp, refining and addition of required chemicals.

4. Production Process:

The pulps are passes to the paper machine and it passes through solid press water
removal. Then it passes through Dryer machine and it passed change calendar
machine next it passes to the online coating machine

5. Size Cutting:

Then passes to the size cutting machine in this machine they cutting the paper bands
according to the customer requirement

6. Finishing Yard:

The finished yard paper boards are passes to the stores or finishing yard.

7. Packaging:

The next step is packing. The workers pack the paperboards in bundles as orders.

8. Documentation:

Before delivering the paperboard to the customers it should be documented in the


stores ledger.

9. Dispatching:

After documentation in proper ledger, the next process is dispatching the goods to
customers.
MPM Inventory Management
BRIEF EXPLANATION ABOUT THE ORGANIZATIONAL STRUCTURE OF
MPM:

The organizational structure of enterprises would depend upon its size, product
manufactured and its fictional divisions. The organizational structure may be flexible.
The company may change its structure according to the needs and suitability.

In MPM Ltd., the Board of directors is having the major position in the company.
The chairman is the chairman cum managing Director (CMD) of the company. He is held
responsible for formulating and implementing the policies, Procedures and rules with the
assistance of Board of Directors appointed by the Government and various financial
institutions. Different functional department heads like production, marketing finance,
and HRD & A etc., also assists him.

The Government appoints the General Manager of HRD & A. He always keeps
contact with all other functional departments for routine administration. He also keeps
direct contact with C.M.D. Each functional department heads are assisted by the
Assistant Managers. The Director of Production is in charge of some divisions’ viz.,
Material, Paper, Pulp, Sugar, Chemical etc., there is always co-ordination between all
functional departments through horizontal communication.

FUNCTIONAL AREAS (DEPARTMENTS) OF MPM:


MPM Inventory Management
MICKINEY’S 7 S MODELS

ORGAN IZA TION STRUCTURE OF THE MPM LTD

SHARE
HOLDERS

BOARD OF DIRECTORS

CHAIRMAN/MANAGING DIRECTOR

DIRECTOR FOREST DIRECTOR FINANCE

G.M.(Marketing) COMPANY
G.M.(Production) G.M. (H.R. D. & P) SECRETAR
Y

AGM.
AGM (PB)
AGM AGM
(MAINT)
(PROJ) (In
(HRD&P)
Change)

AGM

(FIN)
Sr. MANAGER Sr. MANAGER Sr. MANAGER
(Mktg) Sr. MANAGER
(CD) (NP)

(IA)

MANAGERS

DEPUTY MANAGERS

ASST.
MANAGERS
MPM Inventory Management

FINANCE DEPARTMENT

CHIEF OF DIRECTOR
OF FINANCE

ASST. GENERAL MANAGER

SENIOR FINANCE MANAGER

MANAGER OF
MANAGER OF MANAGER OF
CONTROL &
FINANCE IN SALES ESTABLISHMENT
BUDGET

MANAGER
MANAGER MAIN A/C
CORPORATE MANAGER B/P
COSTING
FINANCE

PRODUCTION PROCESS:

Chipper House:-

Chipper house is a place where the different types of wood are cut in to homogeneous
product to heterogeneous and uniform chips.

Activities of Chipper House:-

Receipt of Raw material:-

Raw Material is received in accordance with the production requirement & silo stock of
chips.
MPM Inventory Management

Chipping process:-

Different chippers are run for different raw materials. There are two types of chippers
namely disc chippers & drum chipper. There are two drum chippers used for bamboo &
four disc chippers used for hard wood.

Screening & Conveying:-

Here the accepted chips are sent to the digestion and unaccepted chips are screened and
sent for re-processing.

Storage of chips & issue:-

The accepted chips are stored in silo and issued to digestion process whenever required.

Accounting:-

A record of all the above activities is kept in a systematic manner. Chipper house issues
chips to two streams of pulp mills’

MICKINEY’S 7 S MODELSL : IN PROCESS OF RAW MATERIAL


DEPARTMENT:
MPM Inventory Management
1. Receipt :
• Material loaded vehicle must complete the mill security formalities “Only valid
materials will be accepted”
2. Inspection:
• Material type
• Material Quality and Quantity.
3. Transit documents verification:
• Suppliers particulars
• Material Status
• Validity of supply
4. Weightment:
• Qualification of both received and issued material.
• Prioritize the chipper requirement
• Store as per need, availability in separate stacks and storage potentiality.
• Issue on the basis of requirement of production material mix quality and priority
of period of storage.
5. Yard cleaning:
• Cleaning to prepare the area for further storage
• Cleaning to ensure better utilization of the materials and minimize storage loss.
6. Yard Safety:
• Safety against unfair/ illegal activities like theft.
• Prevent material from other damages.
• Safety against hazards like stacks collapse, fire etc.
7. Accounting:
• Consolidate all the above activities and to generate production report
• Budgeting
• Stock assessment
• Controlling yards loss.
• Reports for finance purpose.
MPM Inventory Management
SWOT ANALYSIS OF THE COMPANY

SWOT analysis is a tool for auditing an organization and its environment. It is the
first stage of planning and helps marketers to focus and key issue. SWOT analysis it is an
effective way of analyzing the organization potential by identifying strength, weakness to
examine the opportunities and Threats which may affect the organization carrying out an
analysis using SWOT tool will be enough to reveal the changes which can be
implemented easily and gain results.

THE SWOT ANALYSIS OF THE MPM IS A FOLLOWS

STRENGTH

• Market leader in paper manufacturing.


• Technical and experience manpower.
• QS9000. ISO9001, ISO14001 (for pollution control) certified company.
• Improved infrastructure.
• Efficient communication network.
• Well planned layout.
• Automated and highly sophisticated machines.
MPM Inventory Management
• Capacity to meet higher demand.
• Additional land of 75000 acres for replanting eucalyptus trees.
• Good marketing network over all India
• Firm is getting raw material quickly for in time production.
• Firm is getting raw material cheaply for the production.

WEAKNESS

• The cost involved in completion of the product is high.


• As the company is in process of decreasing the existing manpower., it may
lose opportunity of obtaining.
• Creative and enthusiastic people in future development of the company.
• As the customer expectations is increasing day by day it has become
difficult to satisfy them completely.
• There is a frequent change in the top management due to political
interference as it is a public sector firm.

OPPORTUNITIES

• Capacity of meeting higher demand and attain optimum utilization of


existing resources.
• Due to advance in technology there is a scope for recruiting and retaining
right people on right job.
• As the company has obtaining six sigma and Qs company has the
capability of achieving global standards’
• Forfeiture of paper industry can be directly linked increase level of
literacy.

THREATS

• Price of raw material is comparatively high.


• Adopting auto motive machines may cause fear among the existing
employees of the job loss, which may morale and the productivity of employees.
• A new entrant is market may dilute the market share of company.
MPM Inventory Management
MPM Inventory Management
ANALYSIS OF FINANCIAL STATEMENT

SUMMARY OF LATEST ANNUAL REPORT:-

It is very essential to keep written record of all the transaction in appropriate


books, which help in calculating the profit and clarifying the financial position of the
company with paper control system one can detect the leakage extravagant and misuse of
fixed assets. The function of the accounts department is to record the various transaction
of the company in financial terms apart from the quantitative records necessary to be
maintained.

As per the balance sheet and profit and loss account of the company there is
decreasing in sales of Rs 42490.72 lakhs in 2009 and RS.33,742.72 lakhs in 2010 and the
company is present academic year it has the loss of Rs. -7,722.56. But the Balance of (-)
loss brought forward from previous year shows that the company is going under loss.

Even if we compare it to the previous year loss was Rs -3202.28(1632.94-


4835.22) in 2009, now it shows -10,924.86 [(Rs -7722.56)- (-3202.28)] in 2010. It shows
that the loss has been increased instead of the decreasing loss / gaining the profit for the
company.

The following statement will show the comparison between the previous years,
2009 and 2010. That will base on the balance sheet and the profit & loss account for the
previous year and current year.

THE MYSORE PAPER MILL LIMITED


PPROFIT AND LOSS ACCOUNT FOR THE YEAR ENDED 31ST MARCH 2010

( RS in Lakhs)
For the year ended For the year ended
PARTICULARS
31.03.2010 31.03.2009
A INCOME
33,742.7 42,490.7
Sales
2 2
761. 32,981.3 1,142.7 41,347.9
Less: Excise Duty & Cess
42 0 4 8
Other Income 1037.37 3132.59
Variation in stocks -2989.11 259.08
31,029.5 44,739.6
6 5
MPM Inventory Management

B. EXPENDITURE
8,139. 9,210
Raw Material Consumed
07 .67
3,415. 4,641
Chemical Consumed
27 .05
765 90
Stores Consumed
.40 3.47
712 1,047
Repair & Maintenance
.46 .18
10,150. 13,680
Power and Fuel
45 .67
1,645. 1,220
Labor charges
78 .40
8,470. 7,042
Employee Benefits
28 .33
1,222. 1,132
Administration and Other Expenses
55 .83
1,443. 78
Selling Expenses
65 8.17
Prior Period Adjustment (net) 68 36,033. 56 40,235.
.48 39 9.00 77
Profit for the year before Interest, 4,503.
C.
Depreciation & Taxation -5003.83 88

Interest 1,864.
D. 1708.86 19
Depreciation 994.
E. 1009.87 86
Taxation-Fringe Benefit Tax 11.
F. - 89
Net Profit for the year 1,632.
-7722.56 94
Add: Balance of Loss (-) brought
forward from previous year -3202.28 -4835.22
Balance of Loss (-) carried to Balance
Sheet -10924.86 -3202.28
MPM Inventory Management

THE MYSORE PAPER MILL LIMITED


BALANCE SHEETAS AT 31ST MARCH 2010
( RS in Lakhs)
For the year ended For the year ended
PARTICULARS
31.03.2009 31.03.2008

SOURCE OF FUNDS
A. SHARE HOLDERS FUNDS
11,889 11,889
Capital .34 .34
55 12,444 59 12,479
Reserve and Surplus 4.76 .10 0.11 .45
B. LOAN FUNDS
4,331 11,323
Secured Loans .57 .58
16,917 21,248 11,717 23,040
Unsecured Loans .27 .84 .27 .85
33,692 35,520
Total A+B .94 .30
APPLICATION OF FUNDS
C. FIXED ASSETS
50,847. 50,574.
Gross Block 42 36
38,612. 37,660.
Less : Depreciation 96 02
12,234.4 12,914.3
NET BLOCK 6 4
590. 12,824.8 209. 13,123.
Capital Work-in Process 35 1 42 76

5,074.4 4,343.
D. CAPTIVE POWER PLANT ATIONS 8 29
62.3 62.4
E. INVESTMENTS 3 4
MPM Inventory Management

CURRENT ASSETS, LOANS AND


F. ADVANCES
10,619. 15,893.
Inventories 49 91
3,395. 5,027.
Sundry Debtors 20 49
1,090. 84.1
Cash and Bank Balance 28 2
2,644. 2,625.
Loans and Advances 37 86
17,749.3 23,631.
4 38

Less: Current Liabilities and


provisions

9,031. 5,961.
Current Liabilities 26 71
3,911. 3,378.
Provisions 62 53
12,942.8 4,806.4 9,340.2 14,291.1
8 6 4 4
22,768.0 31,820.
8 63

MISCELLANEOUS EXPENDITURE
( to the extent not written off or
G. adjusted )
497.
VRS Payments -- 37
H. Profit and loss Account 10924.86 3202.28
33,692.9 35,520.
TOTAL ( C to H ) 4 30
MPM Inventory Management

The above statements are shows the company current situation in the market as
well as the financial position that are all discussing below:-

Analysis of financial statement shows that the danger of imputing companies


economics significance to accounting numbers. The financial information can be
extracted from by using various methods they are as follows:
1) financial ratio

2) Du point analysis

3) Standardized financial statements

4) applications of financial analysis

5) Going beyond the numbers

Some of the few methods we taking for interpretation of financial position of the
company.

Current ratio = current assets \ current liabilities

2009 it was 2.53:1 but in the year 2010 it shows that 1.37:1 it shows that current assets is
more than current liabilities .

Gross profit margin ratio =gross profit \ net sales

In 2009 it was 3.84:1 but in the year 2010 it shows that 2.28:1 it shows that gross profit
margin may reduced to nearly 3times.

Net profit margin ratio = net profit \ net sales

In 2009 it was 7.53:1 but in the year 2010 it shows that 3.23:1 it shows that company is not
in a financial sound position.
MPM Inventory Management

LEARNING EXPERIENCE

In my Ten weeks of project work in Mysore Paper Mill Ltd., I studied and learnt
many things carried in the organization. This project work helped me in gaining more
knowledge about the work and production carried out in the organization.

There is a strict rules followed in HR department and attendance was taken daily
to check the regularity we were used to stay from morning 9.00 AM to evening 5.0 PM
daily and visit different departments daily accordingly to there schedule.

There was a good reaction and co-operation by the superiors and sub-ordinates in
the Mysore Paper Mill Ltd., . They helped me in collection the information regarding the
different departments and production process.

I got the clear picture about the organizational work carried on and how the work
in allotted and how it is carried out and duties and responsibilities of the employees in the
organization. I observed the work techniques that are studied in subject are implemented
in the organization like welfare facility, training techniques etc,.

Finally this project work gave me the clear idea about the working condition in
the organization which will help me in future days.
MPM Inventory Management
PART-B

1. INTRODUCTION:

In recent decade’s businessman have shown an increasing awareness of the need


for precision in the field of inventory control.

In the past, inventories were considered as indication of wealth, even inventories


greatly in excess of the amount needed to carry on the process of production and
distribution were considered beneficial.

Since the advent of modern industries, wealth has become more and more
identified with money. An increased emphasis on the liquidity has led businessman to
hold cash and securities in preference to inventories although the later have an inherent
convertibility not possessed by he other categories. These have been made a strong
tendency towards holding the means for purchase of goods rather than the goods
themselves. Large inventories are now viewed with alarm, where as in times no one
would ever have doubted that such were beneficial.

Every enterprises needs inventory for smooth running its activities. It serves as a
link between production and distribution processes. There is generally, a time lag
between the recognization of a need and its fulfillment. The grater the time-leg, the
higher the requirements for inventory. The unforeseen fluctuations in demand and supply
of goods also necessitate for inventories. It also provides a cushion for future price
fluctuations.

The investments in inventories constitute the most significant part of current


assets/working capital in most of the undertakings. Thus, it is very essential to have
proper control and management of inventories. The purpose of inventory control and its
management is to ensure availability of materials in sufficient quantity as and when
required and also to minimize investment in inventories.

1.2 BACKGROUND OF THE STUDEY:

Inventory in general meaning ‘stock of goods, or a list of goods,’ the word


‘Inventory’ is understood difficultly by various authors. In according language it may
mean finished goods only. In a manufacturing concern, it may include raw materials,
work in process and stores, etc. To understand the exact meaning of the word ‘inventory’
MPM Inventory Management
we may study it from the usage side or from the ‘side point of entry’ in the operations.
Inventory includes the following things.

1. raw materials
2. work in progress
3. finished goods
4. Consumable stores and spares.

A. RAW MATERIALS:
They are the inputs of the final products. They are purchased by the firm
from others and are used in the production for converting into finished
components. The quantity of raw materials required will be determined by the rate
of consumption and the time required for replenishing the supplies. The factors
like the availability of raw materials and government regulations, etc. too affect
the stock of raw materials.

B. WORK IN PROGRESS:
This refers to the goods lying in the manufacturing process. they are
normally practically finished or semi-finished that are at various stages of production
in a multi-stage production process. The raw materials enter the process of
manufacture but they are yet to attain a final shape of finished goods. The quantum of
work-in-process depends upon the time taken in the manufacturing process. The
grater the time in manufacturing, the more will be the amount of work-in-process.

C. FINISHED GOODS:
These are the final or completed products which are ready for sale. The
stocks of finished goods provide a buffer between production and market. The
purpose of maintaining inventory is to ensure proper supply of goods to customer.
In some concerns the production is undertaken on order basis, in these concerns
there will not be a need for finished goods. The need of finished goods inventory
will be more when production is undertaking in general without waiting for
specific order. Work in production, while stock of finished goods is required for
smooth marketing operation. Thus inventory serve as a link between production
and consumption.

D. CONUMABLE STORES AND SPARES:


These are the goods held for consumption by machines in a manufacturing
concern. They include spare parts, lubricants, cleaning materials, oil, cotton waste
etc. they don’t enter into the final product but they are required for maintaining
and running the machines for production purpose.
The levels of the above four kinds of inventories differ depending upon The
nature of the business. For example-A manufacturing firm will have all the four
MPM Inventory Management
kinds of inventories. But a retailer or wholesaler will have a high level of
inventories of finished goods but they will have no inventories of raw materials,
spares, maintenance supplies and stores and goods in progress. Further depending
upon the nature of the business, inventories may be durable or non-durable,
valuable or inexpensive, perishable or non-perishable etc.

Inventory control has been attracting the attention of managers in India for
a long time. But with the credit squeeze measures announced by the government
of India and the consideration of the recommendations of the committee for
inventories top management is deeply a concern with developing suitable norms
for inventory control. In this inventory than the other categories.

1.3 MEANING AND DEFINITION OF INVENTORY:-

The term ‘Inventory’ refers to the stock of raw-materials, spare parts and finished
products held by a business firm. It is the aggregate quantity of material resources and
goods that are idle at a given point of time. The resources may be of any type; for
example men, materials, machinery, money, when resources involved in materials or
goods in any stage of completion, inventory referred to as stock. Hence inventory refers
to the ‘stock’ that a business firm keeps to meet its future requirements of production and
sales.

Several authors have defined the term Inventory. The most popular of them are,
“The term Inventory includes, Raw materials, Work In Progress, finished packaging
spares and other stock in order to meet an unexpected demand or distribution in the
future.”

1.4 ANALYSIS:

Date and information collected are analyzed using statistical tools, graphs and
charts.

2. INTRODUCTION TO COMPANY:

Mysore paper mills Ltd., was established in the year 1937 as a government
company later on in 1947. This company has been converted in to public limited
company.
MPM Inventory Management
The king krishnaraja Wodeyar established this factory to solve unemployment
problem for the Badhravathians and for effective utilization of natural resources.

Mysore Paper mills Ltd., is public based manufacturing company which is


established at Badhravathi. The company produces and supplying of papers such as news
prints. At present the company is meeting the requirement of government departments,
private news print industries and various dealers.

2.1 INVENTORY CONTROL SYSTEM:

Inventories are stock of the product a company is manufacturing for sale and
components that make up the product. The various forms in which inventories exist in a
manufacturing company are raw materials, work in progress, and finished goods. An
inventory control system is to be engineered to achieve the basic purpose for which the
inventories are created. The fundamental objective of a good inventory control system is
to be able to determine, what, when, how much to order, how much to carry in stocks so
as to gain economy in purchasing. An inventory system provides the organizational
provides the organizational structure and the operating policies for maintaining and
controlling goods to be stocked.

Objectives of Scientific Inventory Control System:

The main objective of inventory control management that to be considered by the


analyst while designing

1. Continuity of productive operations.


2. Effective use of capital.
3. Reduction of administrative work load.
4. Service to customers.
5. Economy in purchasing.
6. Reduction of risk of loss.
7. Practical system.
8. Administrative simplicity.
9. To maintain a minimum investment in inventories to maximize profitability.

2.2 STATEMENT OF PROBLEM:

* Lack of new technological information system

* Inefficient handling of inventory materials

* Excessive investment in inventories

* Inadequate inventories
MPM Inventory Management
2.3 SCOPE OF STUDY

This study was mainly concentrated on inventory management being adopted by


the company. The purchase procedure followed by the company and further actions for
satisfying the requirement are analyzed.

The company’s procedure for stores will influence more on the level of inventory
of the company. So the study of purchase has vital role to understand the efficient system
of the company.

2.4 OBJECTIVES OF THE STUDY

* To assess the efficiency of inventory management in Mysore paper mills


Limited.

* To evaluate the inventory control techniques of Mysore paper mills limited.

* To analyze the purchase and stores procedures followed by the company.

2.5 METHODOLOGY

2.5.1 LOCATION OF THE STUDY:

The study had been conducted at Mysore paper mills limited Badhravathi.

2.5.2 SOURCES OF DATA

The methodology followed for collecting information is based on

a) Primary data
b) Secondary data

PRIMARY DATA:

The method which was adopted to collect the primary data was personal
interview.

To collect the information regarding the inventory control systems of the


company direct personal interview and discussions was made with the
material manager, marketing manager and sales officer and other staff
members.
MPM Inventory Management
SECONDARY DATA:

For gathering secondary data various other source were used. They are:

• Different accounting records and annual reports and research report of the
company.
• Published books, magazines, news papers, journals, websites and published
annual reports of the company.
• Different records related to inventory were collected by stores department i.e.
material management stock maintenance.

2.6 LIMITATIONS OF THE STUDY

1. The time constraint which the study has been conducted only for six weeks.
2. The expected delivery schedules may not be possible in some monopoly
items. The average level can be fixed after an in depth study.
3. Level of accuracy of results of research restricted to the accuracy level.
4. The ABC classifications were done for materials and some materials were
selected and studied. The study can be extended to other materials also on the
same lines.

3. REVIEW OF LITERATURE

Sl. Title Findings Source


No

1. Inventory control Inventories constitute second largest Dr. Sukhdev


item after fixed assets in the Singh, Vol-41,
Practice in (IFFCO) financial statement particularly in July 2006
manufacturing organizations. Proper
management of the components is
important to maintain and improve
the health of the organization.

2 Bad goods control in Inventory control mechanism have Prof.


food processing to be built to all points of the supply Mousumi
units chain after a thorough system study, Ghosh Vol-34,
the control aim at maintaining. No.2 February
1999

3 Inventory The study concentrates on Indian P. Janaki


Management of commercial vehicles industry like, Ramudu et al,
MPM Inventory Management
Indian Commercial BTL,EML and SML using and Oct 2006
Vehicles Industry. maintained by more percentage of
raw material where as TML and
EML using less percentage of raw
material and more percentage of
sales. It indicates the TML and EML
is a more strength compare to BTL,
EML and SML.

4 Improving foundry Activity based costing is the current A.N.Roman’s”


performance through cost management. Activities are a Vol-40 Year
activity based powerful and a useful base for 2005
costing managing and enterprise.

5. The Reporting FDI is an important driving force for K.


System of Foreign the growth and development of Ramamoorthy
Direct Investment in nation there is a big competition et al, April \-
India among the nations in attracting FDI. 2003
FDI and issues relating to its
computation provides the much
needed foreign exchange to help
bridge the balance of trade deficit
and technology

6 Activity Based Cost Success of ABM depends on the T Satynaryana


and Management output of an ABC system. ABM can July-Dec2005
help the business organization in
stopping an internal war of numbers.
Better understanding of the business
taking right strategic decision in the
area of product pricing, product
sourcing, product pricing, product
sourcing, product mix and market
segmentation continuous
improvement can be achieved
through ABC & ABM to succeed in
the context of global
competitiveness

7 Globalization cost Globalization has shifted cost Prof Shymmal


management and management paradigm form Banerjee, Cost
MPM Inventory Management
supply chain management of cost from producers Management
management view point to managing costs for Accountant,
greater customer satisfaction in the January 2003
global market where value addition
refers to value creation per unit cost
as the customer sees it and costs
refer to cost of customer retention or
cost of conversion of a customer in
to client

4. ANALYSIS AND INTERPRETATION

In this chapter the whole analysis is divided in to three parts. They are

• To assess the efficiency of inventory management in Mysore paper mills


Limited.
• To evaluate the inventory control techniques of Mysore paper mills limited.
• To analyze the purchase and stores procedures followed by the company.

OBJECTIVE 1

TO ASSESS THE EFFICIENCY OF INVENTORY MANAGEMENT IN MYSORE


PAPER MILLS LTD.

Inventory Management and Control Techniques

The literary meaning of the word “inventory” is stock of goods. Every enterprise needs
inventory for smooth running of its activities. It serves as a link between production and
distribution process. The unforeseen fluctuation in demand and supply of goods also
necessitates the need for inventory. It also provides a cushion for future price
fluctuations.

The purpose of inventory management is to ensure availability of materials in


sufficient quality and quantities as and when required and allow minimizing investment
in inventories. Thus it is very essential to have proper control and management of
inventory.

Activity Ratios or Turnover Ratios at Mysore paper mills ltd..,


MPM Inventory Management
Activity ratios are calculated to measure the efficiency with which the resources
of a firm have been employed. These ratios are also called turnover ratios because they
indicate the speed with which assets are being turned over into sales.

Some of the turnover ratios that are used to know the efficiency of inventory
management in Mysore paper mills lit…, are as follows:

Inventory turnover ratio

Inventory conversion period

Raw material turnover ratio

Stores and spares turnover ratio

Work-in-process turnover ratio

Finished goods turnover ratio

Inventory to working capital ratio

Fixed asset turnover ratio

Inventory Turnover Ratio at Mysore Paper Mills Ltd

Inventory turnover ratio measures the velocity of conversion of stock into sales.
Usually, a high inventory turnover velocity indicates efficient management of inventory
because more frequently the stocks are sold; the lesser amount of money is required to
finance the inventory. A low inventory turnover ration indicates an inefficient
management of inventory. A very high turnover of inventory does not necessarily
implies higher profits. The profits may be low due to excessive cost incurred in replacing
stock in small lots, stock-out situations, selling inventories at very low prices etc.,

The different components of inventory are

• Raw materials.

• Work-in-process.

• Store and spares.

• Finished goods.

Table 4.1 Inventory Turnover Ratio (Rs in Lakhs)


MPM Inventory Management
Years Cost of goods Avg. inventory Ratio
sold

2005 37791.16 11004.83 3.43

2006 40331.81 11274.68 3.577

2007 46860.56 12904.125 3.631

2008 44240.68 14802.155 2.989

2009 45692.28 15617.21 2.926

2010 44667.86 13256.66 3.369

Fig 4.1 inventory Turnover Ratio

The inventory turnover ratio was 3.43 in 2005 and it is decreased to 2.926 in
2009 because inventory consumed and production high but in the 2010 it is increase to
3.369 it is not good compared to previous year and also cost (cost of goods sold) is high.

Inventory conversion period

Table 4.2 inventory conversion period (Rs in Lakhs)

Years Days in year Inventory turn Days


MPM Inventory Management
over ratio

2005 365 3.43 106.41

2006 365 3.577 102.04

2007 365 3.631 100.52

2008 365 2.989 122.11

2009 365 2.926 124.74

2010 365 3.369 108.34

Fig 4.2 inventory conversion period

It may also be of interest to see average time taken for clearing the stocks.
This can be possible by calculating the inventory conversion period. The conversion of
stocks was 106.41 days in 2005 but it is 124.74days in 2009 and it is short period taken to
conversion of stocks compared to previous years that is 108.34days in 2010 and it is good
to organization.

Raw material turn over ratio:

It is the ratio with which we can measure the efficiency with which the firm
converts raw materials in to work in progress. Materials consumed can be found out as
opening balance of raw materials plus purchase minus closing balance of raw materials.
MPM Inventory Management
Table 4.3 Raw material turn over ratio: (Rs in Lakhs)

Years Sales Raw material Ratio

2005 32128.00 7530.62 4.266

2006 34927.31 9116.53 3.83

2007 41519.00 6609.52 6.282

2008 39405.00 6449.79 6.109

2009 42490.00 9210.67 4.613

2010 33743.00 8139.07 4.146

Fig 4.3 Raw material turn over ratio

This ratio indicates the relationship between the sales and raw materials.
In the year 2005 it was 4.266 and it is increase to 6.282 in 2007 there is strong
relationship between sales and raw materials but in 2010 it is decrease to 4.146 it shows
decrease the efficiency of the firm.

Stores and spares turnover ratio:

Table 4.4 Stores and spares turnover ratio:(Rs in Lakhs)

Years Sales Stores and spares Ratio


MPM Inventory Management
2005 32128.00 3255.18 9.869

2006 34927.31 3582.61 9.75

2007 41519.00 3472.37 11.957

2008 39405.00 3589.32 10.978

2009 42490.00 3880.78 10.948

2010 33743.00 3797.60 8.88

Fig 4.4 Stores and spares turnover ratio

This ratio indicates the relationship between the sales and stores and
spares. In the year 2005 it was 9.869 and it is increased to 10.948 in the year 2009 and it
is decrease to 8.88 in 2010. so this origination is not using stores and spares properly so
it is effect to production decreases.

Stock in process turn over ratio:

Table 4.5 Stock in process turn over ratio: (Rs in Lakhs)

years Sales Stock in progress Ratio

2005 32128.00 86.02 373.49

2006 34927.31 86.82 402.295

2007 41519.00 101.25 410.06


MPM Inventory Management
2008 39405.00 134.45 293.08

2009 42490.00 142.56 298.05

2010 33743.00 94.31 357.78

Fig 4.5 Stock in process turn over ratio

This ratio shows the relationship between the sales and stock in process. It
was 373.49 in the 2005 but it is decreased to 298.05 in the year 2009. But in the 2010 it is
increased to 357.78 it is not good to organization because stock in process turn over ratio
is should be decrease and stock in process could be increase so it is better to origination.

Inventory to working capital ratio:

Table 4.6 Inventory to working capital ratio: (Rs in Lakhs)

Years Inventory Working capital Ratio

2005 1104.83 6861.55 1.604

2006 11544.45 6441.72 1.792

2007 14263.80 11682.83 1.221

2008 15340.51 10409.35 1.474


MPM Inventory Management
2009 15893.91 14291.14 1.112

2010 10619.49 4806.50 2.20

Fig 4.6 Inventory to working capital ratio

This ratio determines the connection between inventories to working capital. It was 1.604
times in 2005 but it is decreased to1.112 times in 2009.but in 2010 it is increased to 2.20
so it is good to organization because the working capital consumption is decreases. (i.e
day to day transaction cost is decrease) so that indicates the organization is good at cost
reduction.

Fixed asset turnover ratio:

Table 4.7 fixed asset turnover ratio:(Rs in Lakhs)

Years Sales Fixed assets Ratio

2005 32128.00 16268.63 1.97

2006 34927.31 15409.83 2.27

2007 41519.00 14660.64 2.83

2008 39405.00 13745.73 2.87

2009 42490.00 12914.34 3.29


MPM Inventory Management
2010 33743.00 12234.46 2.76

Fig 4.7 fixed asset turnover ratio

This ratio indicates the extent, which the investment in fixed assets contribution
was 1.97 times in the year 2005. And it has increased to 3.29 in 2009. But in 2010 it is
sudden changes (i.e. decreased) In fixed assets turn over ratio that is 2.76 because of huge
changes in sales so the fixed assets turn over ratio decreased.

ANNUAL PRODUCTION

The following table is shows about the annual production in Metric Tones in the MPM

YEAR PRODUCTION

2005-06 2654.32

2006-07 2784.51

2007-08 2889.51

2008-09 3060.32

2009-10 1797.35
MPM Inventory Management

Production activity can be show in the following graph it is easy to understand the
capacity of production of the paper in MPM.

OBJECTIVE2

TO EVALUATE THE INVENTORY CONTROL TECHNIQUES OF MYSORE


PAPER MILLS LIMITED.

ABC ANALYSIS

Large number of firms has to maintain several types of inventories. It is not


desirable to keep the same degree of control on all the items. The firm should pay
maximum attention to those items whose value is the highest. The firm should therefore
classify inventories to identify which items should receive the most effort in controlling.
The firm should be selective in its approach to control investment in various types of
inventories.

The high value items are classified as

A-items and would be under the tightest control.


MPM Inventory Management
‘B’ items fall into between these 2 categories and require reasonable attention of
management.

‘C’ items represent relatively least value and would be under simple control.

ABC analysis enables to exercise selective control when the materials manager is
confirmed with a large number of items. The significance of this analysis is that it spot
lights attention to be given in respect of the areas like.

• Loss
• Wastage
• Scrap
• Quality
• Price variance
• Usage variance
• Inventory turnover etc.
It also helps to determine safety stocks frequently of ordering preparing of
control statements sources from which material is to be procured etc. hence ABC
analysis is one of the best technique of inventory control.

Advantages of ABC analysis:

• To minimize purchasing cost and carrying cost


• Cost minimization and profit maximization.
• Closer and strict control on these items, which represent a high portion of total
stock value.
• Ensuring availability of suppliers at all times
• Clerical cost can be reduced
• Inventory is maintained at optimum level and there by investment in inventory
can be regulated and will be minimum
• Equal attention to A B and C items are not desirable as it is expensive
• Maintaining enough safety stock for C item
MPM Inventory Management
• Interpretation
From the ABC analysis Mysore paper mills limited (here took major group
of row materials for the analysis) it is clear that A class items that is high value
item, constitute for 70.88% of annual inventory consumption and B class items
constitute 22.05% of total annual value and 22.22% of total item this class is
called as middle classed value item. When compared to a class this inventory
required less control and C class item constitute 6.976% of total annual value and
55.58% of total item, this is called low value terms. So the control on this
inventory does not require when compare to the A and B class items.

ABC analysis is showing table 4.8, 4.9 & 4.10

Table 4.8 Consumption price Data of 20 Items of Mysore Paper Mills limited.

No. Item description Price Annual Annual Rank


Of (per usage Consumption
Items unit) (in MT)

1 Caustic soda lye 23113 7000 161791000 1

2 Liquid chlorine 8056 4200 33835200 6

3 Burnt lime 5385 23000 123855000 2

4 Hydrogen peroxide 33214 3200 106284800 3

5 Soap stone powder 6000 9000 54000000 4

6 Ferric Alum 6175 600 3705000 12

7 Non Ferric Alum 8086 1500 12129000 9

8 Sodium Silicate 8490 1300 11037000 10


MPM Inventory Management
9 Hydrochloric acid 4112 420 1727040 15

10 Sulphur 11151 160 1784160 14

11 Rosine 20000 500 10000000 11

12 Plastic Plug (no’s) 6.25 432000 2700000 13

13 Colors 128 750 96000 18

14 Gum tape (no’s) 51 10800 550800 16

15 Mother liquor 1152 22440 25850880 8

16 M P steam 1200 390 468000 17

17 Reel Core (no’s) 400 132000 52800000 5

18 A T will Gunny Bags 62 425000 26350000 7


(no’s)

Table 4.9 Revised table with items arranged according to their respective ranks

No Item Annual Cumulative Cumulative Category


Of description consumption annual Annual
Items value consumption consumption
value Percentage

1 Caustic soda lye 161791000 161791000 25.72% A

2 Burnt lime 123855000 285646000 19.69% A

3 Hydrogen 106284800 391930800 16.89% A


peroxide

4 Soap stone 54000000 445930800 8.58% A


powder

5 Reel Core (no’s) 52800000 498730800 8.39% B

6 Liquid chlorine 33835200 532566000 5.37% B


MPM Inventory Management
7 A T will Gunny 26350000 558916000 4.18% B
Bags (no’s)

8 Mother liquor 25850880 584766880 4.11% B

9 Non Ferric Alum 12129000 596895880 1.92% C

10 Sodium Silicate 11037000 607932880 1.75% C

11 Rosine 10000000 617932880 1.58% C

12 Ferric Alum 3705000 621637880 0.58% C

13 Plastic Plug 2700000 624337880 0.42% C


(no’s)

14 Sulphur 1784160 626122040 0.28% C

15 Hydrochloric 1727040 627849080 0.27% C


acid

16 Gum tape (no’s) 550800 628399880 0.087% C

17 M P steam 468000 628867880 0.074% C

18 Colors 96000 628963880 0.015% C

Table 4.10 Summary of ABC Analysis of 18 Items

No of % of Range of Total Percentage Category


items items annual annual annual
usage usage usage

4 22.22 Above Rs 445930800 70.88% A


110000000

4 22.22 Between 138836080 22.05% B


MPM Inventory Management
15400000
8640000

10 55.55 Below Rs 44197000 6.976% C


8000000

ECONOMIC ORDERING QUANTITY:

One of the major inventory management problems to be resolved is how much


inventory should be added when inventory is replenished. The EOQ should be applied to
Mysore paper mills ltd for the purpose of many units should be issued for production
department as per production schedule. The will involves the ordering cost and carrying
cost. For analyzing the EOQ techniques company’s 2 years raw materials data should be
taken it should be presented and calculated.

It is the fixed quantity of material which is ordered when the stock comes down to a
reorder level, so that cost of purchasing is equal to cost of storage making the total
inventory cost minimum.

There are various ways of determining the EOQ, such as setting out a tabulation of cost
for various order quantities until the minimum cost is determined or by formula or by
using a graph. The most convenient way is the following formula:

EOQ = √ 2 * Cost of placing an order * Demand for the period

Purchase price per unit * cost of storage as % of total landed cost

The EOQ applied to Mysore paper mills ltd raw materials for 2 years. The
company’s EOW units will be varied in 2 year because of quantities issued to the
production department will be change the year after year. If the consumption rates will
increase the quantities of raw materials should also be increased for the production. The
every item in EOQ techniques presented in table will be used for paper production.
MPM Inventory Management
In 2008 the quantity should be minimum units 9503, when compare to year 2009
is units 10032. If the company is ordering as well as carrying cost will also increase every
year and these cost are different for different items in the company.

The ordering and carrying cost will be the main elements for the paper
manufacturing units. If the companies carrying cost will occurred by way of loss due to
pilferages, wastages and breakages in the sores and the ordering cost will occur by way of
transportation of items from one place to another place. Economic Ordering and
Quantity is shown in table 4.11.

Table 4.11 calculation of Economic Ordering Quantity for two years:

No of Items 2010: Units 2009: Units


Items
EOQ=√2AO/C EOQ=√2AO/C

1 Caustic soda √2*7000*120/0.8 1449 √2*7800*100/0.70 1493


lye

2 Liquid √2*4200*110/0.8 1075 √2*4400*110/0.80 1100


chlorine

3 Burnt lime √2*23000*80/1 1918 √2*27000*80/1 2079

4 Hydrogen √2*3200*100/0.65 992 √2*3000*100/0.65 961


peroxide

5 Soap stone √2*9000*120/0.75 1697 √2*8500*110/0.75 1579


powder

6 Ferric Alum √2*600*110/0.65 451 √2*1500*100/0.75 632

7 Non Ferric √2*1500*100/0.60 708 √2*1600*100/1 566


Alum

8 Sodium √2*1300*120/0.75 645 √2*2000*100/0.87 678


MPM Inventory Management
Silicate

9 Sulphur √2*160*40/1 114 √2*250*45/0.90 158

10 Hydrochloric √2*420*50/0.75 237 √2*500*50/0.75 258


acid

Total 10032 9503

VED ANALYSIS:

This classification is usually applied for spare parts to be stocked for maintenance
of machines and equipment based on the criticality of the spare parts. The stocking
policy is based on criticality of the items. The vital spare parts are those which can cause
stoppage of the plant if not available usually such spare parts are known as capital or
insurance spares.

The inventory policy is to keep at least one number of vital spares irrespective of its
value. Also spare parts be supplied by manufacturer are treated as

 Vital spare, the stock of which even for as short time will stop production for
quite same time and where the cost of stock out is very high are known as
vital spares.
 Essential spares, the absence for which cannot be tolerated for more than a
few hours a day and cost of low production is high and which are essential for
the production to continue are known as essential spares.
 Desirable spares, those which are needed but their absence for even a will not
lead to stop spare of production.

Interpretation

From VED analysis Mysore paper mills limited (Here took major group of raw materials
for the analysis) It is clear the ‘V’ class item for vital usage of items. It constitute for
85.7% annual inventory consumption of total items of 40% and E class items that is
essential of usage of materials the total annual usage is 11.9% of total consumption 30%
and this class is called as medium class usage item and D class of usage items this
constitute 2.3% of total usage of item. This shown in Table 4.12.
MPM Inventory Management
Table 4.12 VED Usage Data on 10 Items

No. Items Description Annual Rank Cumulativ CAU% Rank

of Usage e of Annual category

Items Usage

1 Caustic soda lye 7000 3 7000 13.89% V

2 Liquid chlorine 4200 4 11200 8.33 V

3 Burnt lime 23000 1 34200 45.65 V

4 Hydrogen peroxide 3200 5 37400 6.35 E

5 Soap stone powder 9000 2 46400 17.86 V

6 Ferric Alum 600 8 47000 1.19 D

7 Non Ferric Alum 1500 6 48500 2.97 E

8 Sodium Silicate 1300 7 49800 2.58 E

9 Hydrochloric acid 420 9 50220 0.83 D

10 Sulphur 160 10 50380 0.31 D

Table 4.13 Summary of VED Analysis for Ten Items

No of items % of items Total annual usage % of annual usage Category

4 40 43200 85.7 V

3 30 6000 11.9 E

3 30 1180 2.3 D

HML ANALYSIS:
MPM Inventory Management
The high, medium and low classification follows the same procedure as if adopted in
ABC classification only difference is that in HML, the classification unit value is a
criteria and not the annual consumption value.

The items are inventory should be listed in the descending order of unit value and it is up
to the management to fix limits for three categories.

HML analysis is useful for keeping control or consumption at departmental levels for
deciding the frequency of the physical verification and for controlling purchase.

Interpretation:

It is clear that H class items that is high value price items, constitute for 60.03% of annual
inventory consumption price, and M class item that is medium level value price that
constitute 31.19% of total annual price and L class items that is low price items constitute
8.78% T this shows in Table 4.14, Table 4.15 respectively.

Table 4.14 Calculation of HML analysis

No of Items Price Annual Annual R Cumulative % Rank


items consump per usage consump a annual unit catego
tion unit tion n price price ry
k

1 Caustic 2311 7000 1617910 2 23113 20.31 H


3 00
soda lye

2 Liquid 8056 4200 3383520 6 31169 7.08 M


0
chlorine

3 Burnt 5385 23000 1238550 9 36554 4.73 L


00
lime
MPM Inventory Management
4 Hydroge 3321 3200 1062848 1 69768 29.19 H
4 00
n

peroxide

5 Soap 6000 9000 5400000 8 75768 5.27 L


0
stone

powder

6 Ferric 6175 600 3705000 7 81943 5.42 L

Alum

7 Non 8086 1500 1212900 5 90029 7.10 M


0
Ferric

Alum

8 Sodium 8490 1300 1103700 4 98519 7.46 M


0
Silicate

9 Hydrochl 4112 420 1727040 1 102631 3.61 L


0
oric acid

10 Sulphur 1115 160 1784160 3 113782 9.8 M


1

Table 4.15 Summary of HML analysis for ten items

No. of items % of items Total annual % of annual Category


price price

2 20 56327 49.50 H

4 40 35783 31.44 M
MPM Inventory Management

4 40 21672 19.04 L

OBJECTIVE 3

TO ANALYSE THE PURCHASE AND STORES PROCEDURES FOLLOWED


BY THE COMPANY

The purchasing function occupies a vital and unique poison in the organization of
manufacturing industry. Because purchasing is one of the main functions in success of a
modern manufacturing concerns.

Mass production industries like Mysore paper mills ltd.., since they relay upon a
continuous flow of right materials, demand for an efficient purchasing division.

Under purchase procedure analysis this study considered only, purchasing


procedure for stores, spares, components and raw materials which constitute inventory in
the company. These items constitute a major portion of the total inventories in a
company they include the items needed for proper operation, repair and maintenance
during manufacturing cycle.

Objectives of the purchase Department

The company purchase department stands for following objectives, in order to achieve
competitive advantage in material procurement

i) To procure right material


ii) To procure material in right quantities
iii) To procure material in right quantities
iv) To procure from right and reliable sources
v) To procure material economically, i.e. right or reasonable price.
vi) To receive and deliver materials at
• Right place, and at
• Right time.
MPM Inventory Management

The purchase procedure

Steps involved in the complete purchasing cycle of materials.

i. Recognition of need, receipt and analysis of purchase requisition.


Whenever a department needs an item, it is officially brought the notice
of the purchasing department. Purchase requisition forms the basis for
action by the purchasing department.

ii. Sending purchase requisition to Head Office


In second stage the company stores department sends all orders to head
office, for purchase of required materials.

iii. Selection of possible sources of supply


This process consists of selecting a fair number of vendors in accordance
with established guidelines, from whom quotations will be requested.

iv. Making request for Quotations


In this stage, request for quotations is made on prescribed quotation
forth to all selected (possible) sources of supply.

v. Receipt and analysis of Quotations


After receiving a number of quotations from different suppliers, they
are studied and a comparative statement of rates and other terms and
conditions mentioned in the quotations is prepared.

vi. Selection of right source of supply


The comparative statement as prepared in step (vi)above serves as good
guide in selecting the right source of supply.

vii. Issuing purchase order


After selecting the right supplier, a purchase order is dispatched to them,
to supply respective materials.

A purchase order once accepted by the vendor constitutes a contract for


the delivery of the articles in accordance with terms of purchase
agreement.

viii. Follow-Up and expediting the order


After placing the order, the purchase service selection maintains contact
with the vendor, in order to take corrective actions such as transferring
some of the orders to some other suppliers.
MPM Inventory Management
ix. Analyzing receiving reports and processing discrepancies and
rejections
Receiving reports are compared with purchase order in order to find
discrepancies. Discrepancies found if any during inspection as regards
the quantity or quantity of the received material should be promptly
bought to the notice of the supplier.

x. Checking and approving vendors invoices for payment


Invoices should be checked to ensure that, the correct material has been
supplied, according to agreed terms and conditions. After confirming the
above, the payment is made to the vender for the value of materials
received.

Functions of store department.

I. To receive materials and equipments and to check item for


identification.
II. To record the receipt of materials
III. To correct positioning of all materials and supplies in the store.
IV. To maintain stocks safely and in good condition by taking all
precautions to ensure that they do not suffer from damage,
pilfering or deterioration.
V. To issue items to the users only on the receipt of authorize store
requisitions.
VI. To record and update receipts and issues of materials.
VII. To plan store for optimum utilization of the cubic space i.e.
length, breadth and height.
VIII. To ensure that the required materials are located easily
IX. To initiate purchase cycle at the appropriate time so that the
materials require are never out of stock.

To co-ordinate and co-operate to the full extent with the purchasing,


manufacturing, inspection and production planning and control
departments.

FINDINGS:

Inventory control system: As per the study, raw material has increase
the efficiency of the inventory and drastically has reduced the
transportation cost.

 The company should take in to account of existing stock level when it changes the
design or when it introduces new model otherwise absolute and non moving
stocks will increase due to frequent changes.
MPM Inventory Management

 The employees are very rude behavior and they do not have courtesy to speak
with subordinates and trainees (visitors).

 The Middle class employees are inefficiency and ineffectiveness towards work.

 They do not have proper advanced knowledge to prepare books of accounts.

 Implementation of latest technological systems entrepreneur resource planning


software packages as discussed will cater to the additional information
requirements of the company which in turn will improve the efficiency of
management of inventory control systems.

 For making ABC analysis usually companies consider value and consumption. In
Mysore Paper Mill Ltd., they also consider the value and consumption of raw
materials. This is one of the best evaluations of ABC analysis in which the
company has developed.

 The employees are not interest to give any information to trainees.

 There is no co-ordination between employees.

 The company is making open order for the whole year to the supplier and the
plants according to monthly schedule produce the inventories.

 The stores should be according to the needs of the company this will provide
effective safe and good storage system.

 The company should adopt latest technology to provide a competitive product


which can control inventory and increase profitability of the company.

RECOMMENDATION:

 There is always a threat from the domestic players and a potential threat from the
MNC is for the MPM so it is desirable to contract effective barriers to reduce
competition.
MPM Inventory Management
 The MPM should also concentrate on the diversification so as to ensure expansion
and to utilize the unexploited opportunities.

 As the dealers are not satisfied by the margin offered by the company, it should
increase the margin for the dealers who have been utilized both for selling and
collecting marketing information.

 The company should also target on the high customers who from the customer
base from the MNCs.

 The company should invest on more on R&D to come up with new varieties of
paper in a cost effective manner.

 The company has use various technologically advanced media such as the
internet, mobile, advertising and digital displays to promote its products apart
from the conventional media.

 It should periodically contract its dealers and customer and should review its
performance.

SUGGESTIONS:

As per the study inventory management and its implementation in


Mysore Paper Mill ltd.., it was revealed that management of the inventories play
strong role in the success of the organization.
MPM Inventory Management
 Implementation of better and new information system entrepreneur resource
planning, software packages, as discussed will cater to the additional information
requirements of the company which in turn will improve the efficiency of
management of inventory control system.

 For making ABC analysis usually companies consider value and consumption. In
Mysore Paper Mill Ltd.., they also consider the value and consumption of the raw
materials. This is one of the best evaluation of ABC analysis in which the
company has developed.

 The store should be moderate according to the needs of the company. This will
provide effective, safe and good storage system.

 The company is making open order for the whole year to the supplier and the
plants according to monthly schedule produce the inventories.

 The company should follow the first in first in first out method in issuing the
materials to the production department.

 These materials issuing practices are doing well and have more contribution
towards effective material management. It helps a lot in achieving effective
inventory control over the materials in the company.

 The Company which is give more concentrate on employees benefit for the
current year (i.e. the employees benefit which increased compared to previous
year) that has to be reduce.
 The company which gives more cash discount on sales so this is not good for
organization.
 Employers do not use any set of safety helmets and also. So it makes
compulsory use of safety helmets while doing the work which helps to the
efficiency and health of employees.

 The company can consider by producing the other varieties of paper like cards,
drawing paper etc.

 Excessive labor in certain department they should try to remove the labor.

CONCLUSION:

The control of inventories is complex of many fluctuation and forms.


Inventory are the results of all fluctuation areas (i.e. production, marketing, purchasing.)
with in the organization. The control of inventories represents a shared responsibility and
MPM Inventory Management
viewed as such. Any set of roles used for inventory controls in revalued regularly in
Mysore paper mills ltd..,

In Mysore paper mills ltd.., the purchase and stores department are handling
inventory inefficiently in the organization due to the problem of inadequate technology
and inexperienced employees. They are maintaining ancient method of books of accounts
and it carried high cost and there is no proper utilization of funds. The major factor which
is effect the whole organization that is conflict (agency cost) which is high.

The MPM ltd…, which is run good at production, apart from that the other over
heads (i.e. factory, office and administration, and selling and distribution expenses.) are
high. So the company should reduce the cost which helps to improve the organization.

It is government undertaking. It is running in loss. Due to the above condition. I


wish this company a grand success in the years to come.

5. ANNEXURE

Profit and loss account and Balance Sheet are shown below:

31st the profit and loss account for the year ended march 2010

(Rs. In lakhs)

particulars For the year For the year


ended 31-3- ended 31-3-
2010 2009

Income 42490.72

sales 33742.72 1142.74

Less: excise duty 761.42

32981.30 41347.98

Other income 1037.37 3132.59

Variation in stock -2989.11 259.08

total 31029.56 44739.65

Expenditure
MPM Inventory Management
Raw materials 8139.07 9210.67
consumed

Chemicals consumed 3415.27 4641.05

Stores consumed 765.40 903.47

Repairs & 712.46 1047.18


maintenance

Power and fuel 10150.45 13680.67

Labour charges 1645.78 1220.40

Employee benefits 8470.29 7042.33

Administration and 1222.55 1132.83


other expenses

Selling expenses 1443.65 788.17

Prior period 68.48 569.00


adjustment

total 36033.39 40235.77

Profit/loss for the year -5003.83 4503.88


before interest,
depreciation &
taxation

Interest 1708.86 1864.19

depreciation 1009.87 994.86

Taxation-fringe 0.00 11.89


benefit tax

Net Profit/loss for the -7722.56 1632.94


year

Add: balance of loss(-) -3202.28 -4835.23


brought forward from
previous year

Balance of loss(-) - -3202.28


carried to balance 10924.86
sheet
MPM Inventory Management

THE MYSORE PAPER MILLS LIMITED

BALANCE SHEET AS AT 31 MARCH 2010

(Rs. In Lakhs)

particulars As at 31-03-2010 As at 31-03-2009

SOURCE OF FUNDS

A. SHARE HOLDERS FUNDS

Capital 11889.3 11889.3


4 4

Reserves and surplus 554.76 590.11

12444.10 12479.45

B. LOAN FUNDS

Secured loans 4331.57 11323.5


8

Unsecured loans 16917.2 11717.2


7 7

21248.84 23040.85

Total (A+B) 33692.94 35520.30

APPLICATION OF FUNDS:

C. FIXED ASSETS

Gross block 50847.4 50574.3


2 6

Less: depreciation 38612.9 37660.0


6 2

NET BLOCK 12234.4 12914.3


6 4

Capital work-in progress 590.35 209.42


MPM Inventory Management
12824.81 13123.76

D. CAPTIVE FOREST 5074.48 4343.29


PLANTATIONS
E. INVESTMENTS 62.33 62.44

F. CURRENT ASSETS, LOANS


AND ADVANCES:
Inventories 10619.4 15893.9
9 1

Sundry debtors 3395.20 5027.49

Cash and bank balances 1090.28 84.12

Loans and advances 2644.37 2625.86

17749.34 23631.38

Less: current liabilities and


provisions:

Current liabilities 9031.26 5961.71

provisions 3911.62 3378.53

12942.8 9340.24
8

Net current assets 4806.46 14291.14

Total 22768.08 31820.63

G. MISCELLANEOUS
EXPENDITURE
• VRS payment-note: 4.13 0.00 497.37

H. Profit and loss account 10924.86 3202.28

TOTAL (C to H) 33692.94 35520.30


MPM Inventory Management

5. BIBLIOGRAPHY

 WEBSITES:
 www.mpm.co.in
 www.mysorepapermill.co.in

 Paper mill monthly magazines.

 MPM quarterly magazines.

 73rd , 74th and 75th annual reports. (till 2010)

 Cost accounting- Jawaharlal- TMH, 3/e, 2003

 Production &operation mgt – k. Sridhar Bhat.

 Production &operation mgt –


prof. K. Aswathappa,

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