Inventory Management Rekha Final
Inventory Management Rekha Final
LOCOSHED, KAZIPET”
Submitted to
Jawaharlal Nehru Technological University,
Hyderabad
in
Partial fulfilment for the award of degree of
MASTER OF BUSINESS ADMINISTRATION
Submitted by
M. REKHA
10C31E0030
Under the guidance of
MR. RAJ KUMAR
CERTIFICATE
She has completed her project work as per the rules prescribed and submitted to the
JNT University, Hyderabad in partial fulfillment for the award of degree of Master of
Business Administration. It is a bona fide work done by her and has not been
submitted elsewhere either in part or in full for any degree or diploma of any
university earlier.
[ii]
B. RAJ KUMAR Balaji Institute of
MFA, M.Com, MBA, M.Phil., (Ph.D)
Assistant Professor
Technology & Science
Laknepally, Narsampet,
Department of Management Sciences
Warangal – 506 331.
CERTIFICATE
completed his/her project work as per the rules prescribed and submitted to the JNT
Business Administration. It is a bona fide work done by him/her and has not been
submitted elsewhere either in part or in full for any degree or diploma of any
university earlier.
Supervisor
[iii]
DECLARATION
is not submitted to any other University or Institution for the award of any
degree/ diploma/certificate.
Place: Warangal
Date:
M REKHA
H.T.No 10C31E0030
[iv]
ACKNOWLEDGEMENT
his valuable support and guidance from time to time in giving a final shape to the
project.
and my external project guide Mr. PVSSS. APPALRAJU, for rendering me the
Last but not least, also give my sincere thanks to all the people who directly or
indirectly have helped and encouraged me in finding the way collecting the requisite
M REKHA
[v]
ABSTRACT
Every enterprise needs inventory for smooth running of its activities. It serves
as a link between production and distribution process. There is generally a time lag
between the recognition of a need and its fulfilment. The greater the time lag, the
higher the requirements for inventory. It also provides a cushion for future price
fluctuations.
studied as to the real performance and impact of inventory management in the Electric
Loco Shed and the effectiveness of the inventory utilized is learned by the researcher
Therefore there is a need to know the raw material cost. Also, there is great
Kazipet.
This study helps a lot to various departments to take steps to control the
inventory process.
[vi]
TABLE OF CONTENTS
Certificates……........................................................................................................i-iii
Student Declaration.................................................................................................iv
Acknowledgement....................................................................................................v
Abstract.....................................................................................................................vi
List of Tables................................................................................................ ix
List of Figures..............................................................................................x
1.1. Inventory……............................................................................................... 2
1.4. Scope……………….....................................................................................4
1.7. Chapterisation............................................................................................... 6
[vii]
2.8. History of Electrification.............................................................................. 22
References................................................................................................................. 69
[viii]
LIST OF TABLES
TABLE PAGE NO
1. Table – 1 14
2. Table – 2 14
3. Table – 3 19
4. Table – 4 25
5. Table – 5 46
6. Table – 6 51
7. Table – 7 51
8. Table – 8 53
9. Table – 9 54
10. Table – 10 60
[ix]
LIST OF FIGURES
FIGURE PAGE NO
1. Figure – 1 12
2. Figure – 2 12
3. Figure – 3 13
4. Figure – 4 59
5. Figure – 5 64
[x]
CHAPTER - I
INTRODUCTION
[1]
1.0 INTRODUCTION
1.1 INVENTORY
current assets in public limited companies in India. Inventory serves as a link between
may fail ultimately. In environments where an organization suffers from poor cash
flow or lacks strong control over electronic information transfer among all
departments and all significant suppliers, lead times, and quality of materials received,
financing can be either a line of credit or short-term loan made to a company so it can
purchase the inputs to make the product, or purchase the product itself for resale. The
financial manager has the responsibility to ensure that inventories are properly
monitored and controlled. He has to emphasize the financial point of view and
initiate programmers with the participation and involvement of others for effective
a considerable degree by using simple inventory planning and technique which carries
1. Raw materials
2. Work-in-progress
3. Finished goods
[2]
1.2 NEED & IMPORTANCE OF THE STUDY:
operations.
1.3 OBJECTIVES:
ratios
[3]
To find out the continuous supply of raw materials which facilitate for
uninterrupted production.
1.4 SCOPE:
manage the inventory of any physical item – when to order and how much to order.
How much to order is determined by the order quantity. Inventory control is the
process of monitoring inventory status. Although the concept is simple, the process of
getting the right balance can be quite a complex and time consuming task without the
right technology.
In the present study an attempt has been made to learn the actual
management in particular.
When inventory is seriously tracked down, the company will have a lot of scope for
A thorough analysis of the inventory will help the management to know the
short comings, if any. It also helps the company to learn whether the financial position
and capacity.
[4]
1.5 RESEARCH METHODOLOGY & DATABASE:
an important component of the study without which researcher may not be able to
The data used in study was collected from primary & secondary sources,
comparing annual reports & financial statements of the electric loco shed.
Primary data is collected from the original source of information. The primary
Data related to the organization history is collected from the historical record
Information related to the inventory management, its terms, its techniques and
cards and observation of the stores, the employees of store keepers and
discussion with the project guide and other records, and office files. Some of
the data has been collected through discussion with the second level managers.
Secondary data will be collected from the sources like company annual
reports, search engines, websites, magazines and various text books, news papers,
[5]
1.5.2 PERIOD OF THE STUDY:
Since many years ELECTRIC LOCO SHED, KAZIPET has been following
the same inventory management techniques. As such, for the study of my project, five
There may be approximation in calculating ratios and taking figures from the
annual reports.
It is not always possible to make future estimation on the basis of the past as it
The study did not include all the methods of Inventory Management.
The time period taken for the study is limited and hence it may not provide
comprehensive insights.
1.7 CHAPTERISATION:
1. Chapter 1: Introduction
5. Chapter 5: Summary
[6]
CHAPTER-II
ORGANISATIONAL PROFILE
[7]
2.0 ORGANISATIONAL PROFILE
There are people today in who have never travelled on railway but thanks to
the expansion of television network in the country that would have seen the railway
and a locomotive; The Indian railways with more than 14 lakhs employees are the
Established in 1853 when the first train was flagged from Bombay to thane, a
distance of 34km, it has now grown to dizzy heights and is covering more than 62,
484 km. Across the country is the largest network in the world. The Indian railway
have a felt of 8682 diesel locomotives, 1702 electric locomotives and 729 electric
locomotives.
Richard Trevithick was first man to produce rail locomotives. The first was
completed in 1802, nothing of it is known now expect its existence. The first steam
locomotive to run on a public railway was manufactured in 1802. The very like of this
began in India on December 22, 1851 when a small steam locomotive named
―Thomson‖ started to haul some wagons containing earth during the construction of
On Saturday April 16, 1853 the first Indian train (popularly called as
AagGadi) steamed off BoriBunder to Thane a distance of 34km. The train drawn by
three engines covered the 34km. Distance in 70 minutes from Bombay to Thaana. It
had 400 passengers are than 18 lakhs employees, are the largest employers in the
country. Indian railway is the largest in Asia, fourth in the world and also in signalling
[8]
The most widely used engine on Indian Railways before independence
was extensively used on RajputnaMalwa Railways which become the meter gauge
section of the Bombay and central Indian Railway. The first of these engines was built
by dubs and company Glasgow in 1875. From these engines were also manufactured
unit was set up at chittaranjanin 1950. Between 1950 and 1972 this unit manufactured
2351 steam locomotives. During this period the steam locomotive were being
replaced the world over by electrical and electric locos. In India too, manufacture of
electrical and electric locomotives had started. The stamp depicts 2-8-2 class WG.
The fastest train in the world is goods train and why because these
trains will have starting point to destination. Some of the major stations such as
hauls freight trains of 2250 tons and mail trains with 18 coaches. These engines haul
nearly 56 percent of the total freight traffic on the Indian Railway and important mail
and express trains. The electrical locomotive works at Varanasi has a capacity to
The youngest of the nine zonal Railways in India, South central Railway was
born on 1966. In its forty - three year is committed service and path breaking
progress, South Central Railway has built a modern system of the mass transport,
fulfilled the aspiration of the passengers and made a mark for itself in Indian Railway.
Strategically positioned extending from the east coast to west coast in the southern at
[9]
Secunderabad, serves six major states - Andhra Pradesh, Karnataka, Maharashtra,
From the day of steam hauled locomotives and wooden plank seats. South
Central Railway has come a long way into the era of high powered Diesel and Electric
Today SCR is playing a vital role as a catalyst for agricultural and industrial
Railway (SCR) was formed in October 1966 raving out the divisions of Hubli and
Vijayawada from the southern Railway and the divisions of Sholapur and
merging Guntacal of the Southern Railway with South Central Railway and
In just 38 years SCR has laid 322 route kms of now track & 1,220 route kms
of parallel track, converted 2439 route kms of track from meter gauge, and electrified
1557 route kms introduced 46 new empress trains including Rajadhani & Shatabdhi
trains.
1966 to 495 million in 2003. Jump in freight movement from 9 million tons to 106
[10]
million tons & stupendous improvement in earnings from Rs.58.00 crores to Rs.21,
380 crores.
Pioneered the concept of 24 coach express trains with a view to meet the
First lift provided to the foot over bridge (FOB) is at Tirupathi and it is
passengers.
2.3.1 INTRODUCTION:
town of Kazipet which is 12 km north to Warangal Railway station. The Shed was
traffic requirement.
At present, Electric Loco Shed, Kazipet has a homing capacity of 113 electric
locos. The Shed is carrying out all the Inspection Schedules, unusual attentions and
AOH for all the 113 locomotives. Secondary Maintenance is carried out for two
[11]
MEMU rakes in the shed during night time. Apart from this Shed staffs are attending
1) GAZZETTED ORGANISATION:
Figure 1
SR DEE
(SANJEEVA RAO)
ADEE AMM
(K BHARATH KUMAR) (R SHANKARA RAO)
2) ORGANIZATION STRUCTURE:
Figure 2
assistance by senior scales, junior scales, senior subordinate official that man
[12]
management is more effective and is learnt that the industrial relation are excellent
2.3.3 AIM
Trouble free maintains of loco, which can achieve zero failure with optimum
of expenditure and utilization of man power. This clearly indicates job satisfaction
Figure 3
120
99 109 111 111 113 113
100 82 87
80
60
40
20 WAG-7
0
[13]
Table 1
Table 2
1 IA 60 days 4 hours
The development of railways in India started on all sides after successful initial
projects in the west and the east. Indian Railways was under private owners who have
[14]
not endeavoured consolidated efforts to render quality service to the passengers. Later
On 16th April, 1853 the first railway on Indian sub-continent ran over a stretch of 21
miles from Bombay to Thane. The idea of a railway to connect Bombay with Thane,
Kalyan and with the Thal and Bhore Ghats incline first occurred to Mr. George Clark,
1843.The first Indian train steamed off from Bombay (Bori Bunder) to Thane on 16th.
April 1853, at 3:30 P.M. "amidst the loud applause of a vast multitude and to the
locomotives named Sultan, Sindh and Sahib with 400 VVIPs. The formal
inauguration ceremony was performed on 16th April 1853, when 14 railway carriages
The Survey from Calcutta to Delhi was carried out by Mr. Stephenson during
1845-46. The construction of railway line from Howrah to Raniganj was sanctioned
only after 3 years. But by the end of 1853 61 kms of line was ready up to Pandooah.
Two historical incidents denied EIR, the first position in history of railways in India...
The Locomotive Engine and the carriages for both the trains of Bombay and Howrah
were despatched from England almost at the same time, but the ship carrying the loco
for E.I.R. (HMS Goodwin) was misdirected to Australia and the other carrying the
carriages for Howrah sank at Sandheads. Otherwise Howrah would have had the
legacy of running the first train in India. The Locomotive Engine and the carriages for
both the trains of Bombay and Howrah were despatched from England almost at the
[15]
same time, but the ship carrying the loco for E.I.R. (HMS Goodwin) was misdirected
to Australia and carriages for Howrah sank at Sandheads. The other problem faced
was that the line was aligned through Chandernagore (Chandannagar) which was a
French territory at that time. The settlement of this dispute with French rulers of
Chandernagore also took considerable time. The Locomotive reached Calcutta via
Australia and a trial run was made on 28th. June 1854. The coaches for the first train
were however manufactured by two Calcutta based companies Steward & Company
and Seton & Company. Otherwise Howrah would have had the legacy of running the
The first passenger train steamed out of Howrah station destined for Hooghly,
a distance of 24 miles, on 15th August, 1854. Thus the first section of the East Indian
Railway was opened to public traffic, inaugurating the beginning of railway transport
From 15th August 1854, the company ran regular services, morning and
evening, between Howrah and Hugli with stops at Bally, Srerampore and
Chandannagar. The fare ranged from Rs.3 by first class to 7 annas by third class. The
main booking office was on the Calcutta bank, at the Armenian Ghat, and the fare
covered the ferry to the station. At the Howrah end, the station consisted of a tin shed
and a single line flanked by narrow platforms, somewhat to the south of the present
In the South the first line was opened on 1st July, 1856 by the Madras Railway
[16]
miles. The first line was opened on 1st July, 1856 by the Madras Railway Company.
In the North a length of 119 miles of line was laid from Allahabad to Kanpur
on 3rd March 1859. The first section from Hathras Road to Mathura Cantonment was
The F-734 built in 1895 by the Ajmer workshop of the Rajputana Malwa
Railway. Earlier some locomotives were assembled using spares supplied with fully
connecting and side rods was used on Rajputana Malwa & Bombay Baroda & Central
These were the small beginnings which is due course developed into a
network of railway lines all over the country. By 1880 the Indian Railway system had
The railway construction in India took an abrupt boom and a large number of
companies started working. These companies had only one thing in their mind. To
earn enough money. They had no co-ordination in their working and time tables. The
British government was seriously thinking about this. Sir Thomas Robertson who was
of railways submitted his report in 1903. As a result of his efforts the Railway Board
assumed office in 1905. Railway mileage now at about 24,750 miles in India, of
which 14,000 miles are BG, and most of the rest MG (with only a few hundred miles
of 2' and 2'6" gauge lines). Regrouping was first conceived in 1904, but materialised
[17]
2.4.6 THREE TERRITORIAL DIVISIONS WERE FORMED.
Central India (BBCI), North Western, Jodhpur, Bikaner together with branch
2. Eastern Division consisting of: EIR, Oudh & Rohilkund, Bengal & North
Bengal (EBR).
Railway, and being implemented now by Central Railway, for integrated management
and monitoring of suburban train movements and signalling, as well as planning train
covers the major section from CST Mumbai to Kalyan, with four additional minor
Bhiwandi Road on Vasai side beyond Dombivli, and Dativli Chord Cabin beyond
This information is based on WR practice today; CR's TMS will use a very
similar system for identifying each rake and its trips. Each rake has a unique rake unit
number assigned to it. This is entered at the TMS input unit of the driving cab of the
rake, and is broadcast from an antenna mounted on the driving cab. This allows the
position of every rake to be known to the TMS system. Every EMU is also assigned a
[18]
unique train number when it is in service. This number (usually one or two
alphanumeric characters, e.g., 'AR') is assigned (and entered manually into the TMS
system) when the rake leaves the car shed, and also noted at the end of the day when
the rake is stabled. Each EMU also gets a 1 to 4 digit trip number (e.g., '173') for each
trip it makes while it is in service during the day. The trip number directly
corresponds to each run of the EMU in the timetable. As the train passes various
signals and other locations with TMS transponders, the rake unit number is picked up
from the transmitting antenna on the driving cab; this is correlated with the train
number and then the trip number by the TMS computers and the appropriate status
updates are made for the train's position and movement at the TMS units used by
station staff or section / traction controllers, and also for updating the PA systems at
Table 3
Year Total Route Kms Running Tracks Kms Total Track Kms(*)
[19]
2.5.3 STATION SCHEDULING
At each station, based on the train schedules, a platform and siding occupancy
chart is drawn up. This provides, for each day of the week, an indication of which
platforms and sidings are occupied by which trains at what times. Introducing a new
in this chart.
are under the control of the Chief Operations Manager of a division who is ultimately
responsible for the performance of the division in terms of punctuality, efficiency, etc.
Locos, except for older steam ones, have classification codes that identify
In this the first item, '[gauge]', is a single letter identifying the gauge the loco runs on:
W = Broad Gauge
Y = Meter Gauge
Z = Narrow Gauge (2' 6")
N = Narrow Gauge (2')
The second item, '[power]', is one or two letters identifying the power source:
D = Diesel
C = DC traction
A = AC traction
CA = Dual-power AC/DC traction
B = Battery electric(rare)
[20]
The third item, '[load]', is a single letter identifying the kind of load the loco is
M = Mixed Traffic
P = Passenger
G = Goods
S = Shunting
L = Light Duty (Light Passenger?) (no longer in use)
U = Multiple Unit (EMU / DEMU)
R = Railcar (see below)
There are two senses of the phrase "multiple units" to be distinguished. Two or more
regular locomotives may be coupled together for greater hauling capacity. In such a
case the locos are said to be operating as multiple units or to be "MU'ed together" (US
terminology: "lash-up").
This is not to be confused with the terms electric multiple unit (EMU) or diesel
multiple unit (DMU) which refer to cars used for (mostly suburban) train services
which have multiple prime movers (either electric motors or diesel engines) for each
car. I.e., the same car that carries passengers also has the motive power, as opposed to
the normal situation where the passengers are in coaches that are not self-propelling
[21]
2.7 ELECTRIC TRACTION VOLTAGES
The 1.5kV DC overhead system (negative earth, positive catenary) is used around
Bombay (This includes Mumbai CST - Kalyan, Kalyan - Pune, Kalyan - Igatpuri,
Mumbai CST - Belapur - Panvel, and Churchgate - Virar). There are plans [2/04] to
change this to 25kV AC by 2010. In preparation for this, BHEL has been retrofitting
some Alstom EMUs with AC drives to allow them to operate with both DC and AC
traction as the system conversion proceeds (see the section on EMUs). Conversion to
25kV AC has already been done on the Titwala-Kasara section; next to be converted
DC until about 1967, when it was converted to 25kV AC (all overhead catenary
supply). (This is where the MG DC locos were used, e.g., the YCG-1 series.)
The first electric train ran between Bombay's Victoria Terminus and Kurla
along the Harbour Line of CR, on February 3, 1925, a distance of 9.5 miles. In 1926,
Madras Beach and Tambaram was inaugurated (1.5kV DC). After that the only
electrification project undertaken was Borivili - Virar, finished in 1936. For mainline
[22]
traffic, GIPR undertook electrification of the Karjat-Pune and Kasara-Igatpuri
sections because it was realized that the heavy traffic to and from Bombay would be
mentioned above. Since French developments led the field, the AC locomotives
supplied at first (from SNCF) followed that country's practice, whether built in India
or France. These were the eight-wheeled WAM-1 locomotives that are still in
The first train to be hauled by an electric locomotive from Delhi Jn. was the
Assam Mail.
Bombay-Delhi (WR) route was fully electrified by Dec. 1987. The CR route
was fully electrified by June 1990, when the Bhusaval - Itarsi section was electrified.
The 2 * 25kV AC system (see below) began to be put in place in the 1990s; the first
regular service using this system was between Bina and Katni (CR) on January 16,
[12/04] With the BG conversion between Tambaram and Madras Beach complete, the
train uses electric traction (the YAM 1 locomotives used to service this section have
has most of the busy routes of its network electrified (although not all), and this has
resulted in about 65% of the traffic being hauled by electric traction. Recently
[12/04], therefore, IR has decided to slow down the pace of electrification -- about
the busiest sections; some of the sections that will be converted to electric traction in
the next few years are Pune-Guntakal, Bina-Kota, and many 'B' sections of NR.
[24]
2.9.3 DEEMED ZONES:
Table 4
4600, 150
Western 10295 4455 890
BG/NG
2125, 155
Southern 7040 4630 130
BG/MG
This is now found all over the country, and all major passenger and freight routes are
now broad gauge. This is the widest gauge in regular use anywhere in the world. (In
the past, though, an 8' gauge was used in Oregon, USA, and a 7'¼" gauge was used
for the Great Western Railway in the UK.) Outside India, the 5'6" gauge is found in
Pakistan, a spur from Pakistan into Iran, Sri Lanka, Bangladesh, Argentina, Chile, and
the BART rapid transit system in the USA. The decision to use a gauge wider than the
one in use in Great Britain was made with an eye towards economies in freight
[25]
movement, and also to ensure stability in the face of Indian weather and the perceived
This is still found in a lot of places, despite the push to convert everything to
broad gauge. It is said that this gauge was chosen by Lord Mayo (then Viceroy of
have been 3'3" except that there was then a push to move to the metric system and so
the gauge became 1m. The first MG line was built in 1872 from Delhi to Farukh
Nagar (??). Interestingly, the metric system was not after all adopted until nearly a
century later, so the gauge was the only thing in India that was 'metric' for a very long
time.
About 14,500 route km of IR's network is meter-gauge [2/09] (the figure was
to 5,000km or less. The MG network was especially dense in the west (around
Vadodara, and in Rajasthan), in the east / north-east (West Bengal, Assam) and,
before Independence, the areas in what is now Bangladesh), and in much of the south
of India. Until the late 1980s, the North-Eastern Railway had a completely MG
network. The MG networks of northern India (including the north-east via the Assam
Rail Link) and southern India (16,690 and 7940 route kms, respectively) remained
separate until 1960, when the completion of the Khandwa - Hingoli section connected
the two. This link went through Akot, Akola, and Basim, across the Tapti and Purna
rivers and had 2 tunnels and 50 major bridges, and a spectacular spiral. This made
possible the transit of freight from any MG station in India to any other (except, of
[26]
course, the Nilgiri line which was always an isolated MG section), which was
important even though MG's share of freight was never very large (about 12% before
the Unigauge project started). The last MG line to be built in India was probably the
This gauge was adopted in various parts of the British Empire. There were
(still are) considerable networks of these, for example in Gujarat around Vadodara
(mostly from the old Baroda State Railway) and in MP (centred around Gondia on the
converted to BG.) The most well-known line is probably the Kalka–Shimla route. The
rationale for the narrower gauges was economy in building the lines — they could be
laid much faster than broad gauge lines and in more difficult terrain. It was envisioned
that narrow gauge lines would act as feeder lines to the broad gauge and meter gauge
lines, but many became important railway routes in their own right.
A few places in India have the even narrower 2–foot gauge: New Jalpaiguri-
Darjeeling, Neral Matheran, and the Gwalior branch lines, which include Gwalior -
Sheopur Kalan, Gwalior – Shivpuri, and Gwalior – Bhind. (The Gwalior lines in the
past also included the Ujjain–Agar line.) The Howrah-Amta and Howrah-Sheakhala
NG lines were shut down a while back, and are now being rebuilt as broad gauge.
The two narrow gauges together make up about 3700 route km of IR's network.
[27]
2.10.5 STANDARD GAUGE (4'8½" OR 1435MM)
This has been used in a few places in India. The Calcutta tram lines are
probably the most well-known and probably the only surviving example. Heavy rail
in this gauge was used during the construction of the Madras Harbour (3 standard
gauge locos were procured by the Madras Port Trust). Standard gauge was also used
for the original construction of the Bombay Docks (but this system, put in place in
1909, lasted only until 1954). Standard gauge was insisted upon by the contractors for
the Bombay Docks project (Messrs. Price, Willis, and Co.), for the transportation of
material from Elephanta Island and to the new dock works and basin dam. Eight
standard gauge locos were procured for this, four used in Bombay City and four on
The National Rail Museum (NRM) is located in New Delhi. NRM's website has a lot
In addition to the better known and popular outdoor exhibits of plinthed or working
locomotives and other rolling stock, and indoor exhibits of railway equipment, the
NRM has a lot of books, maps, and other publications related to the railways in its
library (access by permission; not open to the public). They have old timetables (all
back to 1970, sparser before that, including the first Trains At A Glance (1977);
annual reports for most of the 20th century, old issues of the Railway Gazette and
other foreign railway publications; annual issues of the History of Indian Railways
Railways up to 1966; and many official Survey of India maps and railway maps.
[28]
2.11.2 MYSORE RAIL MUSEUM
The Railway Museum at Mysore is located adjacent to the Mysore railway station, but
with the entrance on the other side (no direct way to reach it from the station). It is
open daily except on Mondays. Nominal entrance and camera fees are charged. They
[29]
CHAPTER III
THEORETICAL FRAMEWORK
OF
INVENTORY MANAGEMENT
[30]
3.0 THEORETICAL FRAMEWORK OF INVENTORY MANAGEMENT:
Inventory often constitute a major element of the total working capital and
including fixation of minimum and maximum levels; determination the size of the
inventory to be carried; deciding about the issue price policy; setting up receipt and
system with regard to the inventories, the stock items will be provided to the
profitability.
at a high level higher interest and storage costs would be incurred on the other hand, a
low level of inventories may result in frequent interruption in the production schedule
[31]
3.2 DEFINITION OF INVENTORY:
The term inventory refers to the stock of the product a firm is offering for sale
the components that make up the product. The term inventory comprise of raw
material, work in process, finished goods, stores and spares and consumables.
inventory are to manager as they directly show there impact on corporate profits. Any
The cost of the corporation structure of the inventory depends upon the level
of inventory held by it. If inventories are held above required level the cost which
result from handling storage spoilage obsolesce are more if they are maintained at
optimum level.
Search extra cost reduced the profits of the corporation. This effect may cause
when it is under invested. If the maintained level of inventory falls shortage the
corporation has to produce at extra cost to continue its operation. In this situation it is
obvious that more cost may incur. So important is given to inventories so that the cost
management.
To make sure that the materials are available for use in production and
[32]
To ascertain that finished goods are available for delivery to customers to
fulfil orders.
To maintain a large sized inventory for efficient and smooth production and
sales operation.
To place an order at the right time with the right quality at the right price with
right quality.
policies, systems, and procedures which will minimize total cost relative to inventory
inventory to hold. Too less or too much inventory is harmful for any concern because
receiving lists, and payment receipts and can print bar code labels. An inventory
management software system configured to your warehouse, retail or product line will
help to create revenue for your company. The Inventory management will control
operating costs and provide better understanding. We are your source for inventory
[33]
A complete Inventory Management Control system contains the following
components:
Rigid control over materials are necessary not only to guard against theft, But
also minimize waste and measure from causes such as excessive inventories, over
qualities.
Vouchers for the payments of materials purchased will be approved only if the
individual.
[34]
The control of materials, as an element of cost of production, is illustrated
with reference to the purchase and issues procedures, inventory systems, and
inventory control techniques. The efficiency of inventory control agates the flexibility
of the firm. There are several tools of inventory control. Some of these are:
The order point formula which tells us the optimal point at which to reorder a
Together these tools provide the means for determining an optimal average
level of inventory for the firm. Ratio analysis has wider applications measure of
Inventory control refers to a system which ensures supply of required quantity and
quality of inventories.
[35]
3.7 NEED FOR INVENTORY
in environments where an organization suffers from poor cash flow or lacks strong
control over (i) electronic information transfer among all departments and all
significant suppliers, (ii) lead times, and (iii) quality of materials received, inventory
plays important roles. Some of the more important reasons for holding inventory are:
a. Predictability:
to control how much raw material, parts, and subassemblies you process at a given
time. Inventory buffers what you need from what you process.
b. Fluctuations in demand:
much you are likely to need at any given time, but you still need to satisfy customer or
production demand on time. If you can see how customers are acting in the supply
c. Unreliability of supply:
Inventory protects you from unreliable suppliers or when an item is scarce and
accomplished through master purchase orders with timed product releases, price or
between the parties, etc. This will result in a lowering of on-hand inventory needs.
[36]
d. Price protection:
cost inflation. Note that contracting to assure a price does not require actually taking
delivery at the time of purchase. Many suppliers prefer to deliver periodically rather
than to ship an entire year‘s supply of a particular stock keeping unit ( SKU) at one
time.
e. Quantity discounts:
Often bulk discounts are available if you buy in large rather than in small quantities.
If you buy a larger quantity of an item less frequently, the ordering costs are
less than buying smaller quantities over and over again. In order to hold down
ordering costs and to lock in favourable pricing, many organizations issue blanket
purchase orders coupled with periodic release and receiving dates of the SKUs called
for.
a. Basic Categories
i. Raw materials:
partial products or completed goods or finished products, e.g., nuts, bolts, flour, sugar.
This is product ready for current customer sales. It can also be used to buffer
manufacturing company can make up a supply of toys during the year for predictably
higher sales during the holiday season. It includes completed products waiting to be
[37]
iii. Work-in-process (WIP):
Items are considered to be WIP during the time raw material is being
converted into partial product, subassemblies, and finished product. WIP should be
kept to a minimum. WIP occurs from such things as work delays, long movement
b. Functional Categories:
i. Consumables:
Light bulbs, hand towels, computer and photocopying paper, brochures, tape,
envelopes, cleaning materials, lubricants, fertilizer, paint, dunnage, and so on are used
machine or device of some type is being used (in the market) and will need service
and repair in the future, it will never be obsolete. S&R Items should not be treated like
finished goods for purposes of forecasting the quantity level of your normal stock.
needed, on-failure basis, it would need a larger supply of these lights on hand at all
times. However, if the same company relamped all of its ballasts once per year, it
would buy a large quantity of tubes at one time and only keep a small supply on hand
on an ongoing basis. Since S&R Items are never ―obsolete‖ or ―dead‖ until the
equipment or device they are to be used for is no longer in service, these items should
[38]
iii. Buffer/safety inventory:
This type of inventory can serve various purposes, such as: —compensating
for demand and supply uncertainties. —holding it to ―decouple‖ and separate different
parts of your operation so that they can function independently from one another.
sell in the anticipated period could be disastrous because you may be left with
v. Transit Inventory:
This is inventory en route from one place to another. It could be argued that
product moving within a facility is transit inventory; however, the common meaning
of the concept concerns items moving within the distribution channel toward you and
also outside of your facility or en route from your facility to the customer.
Most inventories fit into raw materials, work-in-process and finished goods,
yet the amount of each category varies greatly depending on the specifics of industry
Distribution businesses tend to carry mostly finished goods for resale while
manufacturing companies tend to have less finished goods and more raw materials
and work in progress. Given these differences, it is natural that the accounting choices
In order to assign a cost value to inventory, you must make some assumptions
about the inventory on hand. Under the general income tax laws, a company can only
[39]
make these assumptions once per fiscal year. Tax treatment is often an organization‘s
assumes significance in view of the fact that it has a direct bearing on the cost of
This method of inventory valuation assumes that the first goods purchased are
the first to be used or sold regardless of the actual timing of their use or sale. This
purchased/acquired goods are the first to be used or sold regardless of the actual
timing of their use or sale. Since items you have just bought often cost more than
those purchased in the past, this method best matches current costs with current
revenues. The cost of goods sold and the value of closing inventory can be determined
only after the final lot of the year has been received. This is because of the assumption
underlying the valuation of inventory. As the name LIFO suggests, the use of
This method of inventory valuation identifies the value of inventory and cost
of goods sold by calculating an average unit cost for all goods available for sale
during a given period of time. This valuation method assumes that ending inventory
consists of all goods available for sale. Each purchase is added to inventory and an
[40]
average cost determined. Materials are charged into cost of sales at this average until
another lot is received, when anew average unit inventory cost is calculated.
This method of inventory valuation assumes that the organization can track the
actual cost of an item into, through, and out of the facility. That ability allows you to
charge the actual cost of a given item to production or sales. Specific costing is
for high-value items such as artwork or custom-made items. The materials used are
priced at their actual cost which involves identification of each lot purchased. It is the
simplest but also the most time-consuming method of determining cost of material
used is computed by multiplying the quantity used by the specific price each material.
to give all of their departments a uniform value for an item throughout a given year.
This method is a ―best guess‖ approach based on known costs and expenses such as
historical costs and any anticipated changes coming up in the foreseeable future. It is
not used to calculate actual net profit or for income tax purposes. Rather, it is a
working tool more than a formal accounting approach. It is based on a standard price
for a specified period. A standard price is fixed for each class of materials in advance
after proper investigation. The different between actual price and standard price is
transferred to purchase price variance which reveals to what extent actual costs are
[41]
6. BASE STOCK PRICES METHOD:
The base stock refers to the minimum quantity of stock of materials that a firm
has to maintain at all times. Under this method it is assumed that the minimum stock
which must always be carried is in the nature of fixed assets, and is never realized
while the business continues. The minimum stock is carried at original cost of
acquisition. The quality of material in excess of the base stock is available for the
Under this method material are issued at the price at which they can be
replaced, that is at the market price prevailing on the date of issue. This method could
which are either absolute or lying unused for a long time in store.
ensures supply of required quantity and quality of inventories at the required time and
Reorder Point
ABC Analysis
Safety Stock
[42]
3.10.1 ECONOMIC ORDER QUANTITY:
Determination of the quantity for which the order should be placed is one of
order refers to the size of the order which gives maximum economy in purchasing any
item of raw material or finished product. One of the major inventory management
replenished.
ORDERING COST:
This is the cost of placing items an order and securing the supplies. It varies
from time to time depending upon the number of orders placed and the number of
items ordered.
obsolescence losses, store-keeping cost, insurance premium etc. The large value of
inventory, the higher will be the inventory carrying cost and vice versa.
The former cost may be referred as the ―cost of acquiring‖ will the later as the ―cost
of holding‖ Inventory.
FORMULA:
C = consumption
[43]
ASSUMPTIONS:
1. The firm knows with certainty the annual usage of a particular item inventory.
2. The rate wish the firm uses inventory is steady over time.
3. The orders placed to replenish inventory stocks are received at exactly the
APPROACHES OF EOQ:
depending upon the inventory planning horizon, a firm has different alternatives to
purchase its inventory. For instance it can by its entire requirements in one single lot
The economic order quantity can using a shortcut method, be calculated by the
following equation.
minimize the carrying as well as the ordering costs. In other words, the EOQ provides
on answer to the question. How much inventory should be ordered in one lot?
[44]
Another important question pertaining to efficient inventory management is which
The Reorder point is stated in terms of the level of inventory at which on order
should be placed for replenishing the current stock of inventory. In other words,
reorder point may be defined as that level of inventory when a fresh order should be
placed with the suppliers for procuring additional inventory to the economic order
quantity.
The reorder point = lead time in days X Average daily usage of inventory.
Here lead time refers to the time normally taken in receiving the delivery of
The technique is based on the assumption that a firm should not exercise the
same degree of control on all items of inventory. It should rather keep more rigorous
2. Slowest-turning
[45]
3.10.3 ABC ANALYSIS
study of product inventory levels. It is also means ―Always Better Control‖, inventory
in terms, which are not being consumed. The spares which are having nulled
done among the items, which are having consumption value greater that zero, for easy
segregation. RAIL WAY ELECTRIC LOCO SHED has classified ABC as following.
Table 5
[46]
For finding an items as A, B or C the annual value of consumption in the
preceding financial year shall be the basis to start with the item are identified as A, B
or C based on moving average concept to take care of situation more realistically, the
He is holding powers,
The spares, which are having nil consumption in a financial year are called ‗D‘
class item in a power for the next year we shall to divert more attention towards
inventory value then consumption value , so major attention is required for higher
XYZ ANALYSIS:
This is based on the value of inventory stored. If the value is high special
efforts should be made to reduce them. This exercise can be done once a year. Items
Y= Inventory value more than Rs.1, 00,000 to less than Rs.5, 00,000
[47]
VED ANALYSIS:
This type of analysis is applicable mostly in the case of spare parts. The
peculiarity about spare parts is that they do not follow a predictable demand pattern as
V = Vital
E = Essential items
D = Desirable items
FSN ANALYSIS:
This analysis takes in to account the pattern of issued from stores. The 3 letters stands
In the example given above the recorder level was computed presuming that
there is no uncertainty regarding the usage as well as the lead time. In actual practice,
it is almost impossible to correctly predict both of them. The actual usage as well as
the lead time may be different from the normal usage or the normal lead time. The
[48]
CHAPTER-IV
[49]
4.0 DATA ANALYSIS & INTERPRETATION
KAZIPET:
services to the Indian railway sector those are here one section is repair the
express repair section, the second section is normal loco belongs to half yearly
and quarterly and minor repair section the last one is normal locomotive
organization has here Three inventory store and issue section those are
9.36 corers, and here inventory in terms are 546 types. These 546 types of
inventory items are divided into sub categories like safety, vital items, nil items
FIRST OUT and LAST IN FIRST OUT methods are mostly used methods.
Here any inventory item arise surplus and died surplus. The died surplus value
declared by the survey committee consists two section engineers and two
[50]
Table 6
CATEGORY
ITEMS VALUE NNR HDG
CLOSED
A 54 6.15 CRORE 05 01
B 132 2.19 CRORE 07 -
C1 232 0.91 CRORE 32 02
C2 128 0.07 CRORE 20 02
TOTAL 546 9.36 CRORE
A CATEGORY 22
B CATEGORY 85
C CATEGORY 280
STOCK VERIFICATION:
Table 7
CATEGORY STOCK VALUE OF
INVENTORY
A 10% 70%
B 70% 20%
C 20% 10%
[51]
ANALYSIS OF INVENTORY ITEMS OF WARD-01
Rs.5.22. These items classified in to six categories those are safety items, vital
category C2 determine the less than 3.25 lakhs value items comes under the
category C. The second major items are category B items. This category
determine by the value of more than 3.25lakh and less than 22 lakh value items
electricity and general items this is second important ward in the organization.
So generally all spare parts value as less than 3.25 lakhs. So this category a has
[52]
4.3 GENERAL WARD 02
A CATEGORY 31
B CATEGORY 47
C CATEGORY 79
STOCK VERIFICATION:
Table 8
NUMBER OF NUMBER OF
CATEGORY PERIOD
ITEMS ITEMS UNIFIED
A 31 - 6 months
B 47 - 1 year
C 79 - 2 year
This ward consist of 157 inventory items all this items are classified
into 6 categories those are Safety items, Vital items, category A, category B,
category C and NIL items. This ward belongs to the mechanical items ward
[53]
like cable, batteries and filters etc., this ward average annual consumption is
2.49 crores.
CATEGORY A
Table 9
[54]
APRIL 2007 1000 300 900
[55]
JULY 2008 - 520 1648
[56]
OCTOBER 2009 - 482 1231
[57]
CLOSING BALANCE 2010 544 420 1230
MAY 2011 - - -
JUNE 2011 - - -
OCTOBER 2011 - 47 57
[58]
Figure 4
10000
8000
6000 RECEIPTS
ISSUES
4000 BALANCE
2000
0
1st QTR 2nd QTR 3rd QTR 4th QTR
INTERPRETATION
When we compare with these three years information the following
1. In 2008 receipt was 2353 units issues 3749 units the surplus item are
2. In 2009 receipt was 7376 units issues 6170 units the surplus item are
3. In 2010 receipt was 4970 units issues 7050 units the surplus item are
4. In 2011 receipt was 2525 units issues 3644 units the surplus item are
[59]
BIN CARD
CATEGORY B
WARD: 02
[60]
SEPTEMBER 2007 - 220 326
CLOSING
- 418 434
BALANCE 2007
OPENING
- 418 434
BALANCE 2008
AUGUST 2008 50 90 10
SEPTEMBER 2008 55 55 10
OCTOBER 2008 40 40 10
[61]
DECEMBER 2008 1000 413 602
CLOSING
1000 413 602
BALANCE 2008
OPENING
1000 413 602
BALANCE 2009
CLOSING
- 356 11058
BALANCE 2009
[62]
BALANCE 2010
CLOSING
- - 10039
BALANCE 2010
OPENING
- - 10039
BALANCE 2011
[63]
MARCH 2011 - 470 7779
Figure 5
10000
9000
8000
7000
6000 RECIEPTS
5000 ISSUES
4000 BALANCE
3000
2000
1000
0
1st QTR 2nd QTR 3rd QTR 4th QTR
[64]
INTERPRETATION
1. In 2008 receipt was 2600 units issues 3776 units the surplus items are
2. In 2009 receipt was6000 units issues 5144units the surplus items are 856
3. In 2010 receipt was 4687 units issues 5706units the surplus items are
4. In 2011 receipt was 300 units issues 4725units the surplus items are
[65]
CHAPTER-V
SUMMARY
BIBLIOGRAPHY
[66]
5.0 SUMMARY
In the light of the above discussion the following findings and conclusions are
made:
This chapter deals with presentation of the summary of the work done. It also presents
a very important role. The organization, Electric loco shed Kazipet of South Central
Railway is chosen for applying inventory control techniques to control the wastage
Therefore this chapter deals with presenting a total financial picture of railway.
months for ―B‖ category and 12 months for ―C‘ category respectively.
The organization structure of the department of Electric loco shed, Kazipet depicts the
The stores department is divided into wings rolling stock and work shop
facilities Rolling stock which comprise of loco motives, coaches and wagons. Work
[67]
Electric loco shed is adopting periodic stock verification method for the
verification of stock. It is adopting book average price and purchasing rate for
Electric loco shed following ABC analysis as a part of their inventory control
techniques. It has been classified into three categories they are ―A‖ category items. In
this category all repetitive items are generally controlled by applying the ABC
analysis.
In Electric loco shed - Kazipet the classification of materials, in ―A‖ ―B‖ and
―C‖ category is based on the cost of items. All the items whose value is above Rs 5
Lakhs is included in category ―A‖ and whose value is less than 5 lakhs is included in
category ―B‖ and remaining items whose values is less than 3 lakhs is included in
category ―C‖.
Electric loco shed Kazipet has been using ABC analysis coupled with VED
analysis for control and remaining items whose values is less than 3 lakhs is
[68]
BIBLIOGRAPHY
Chandra, Prasanna., (2008). Financial Management, New Delhi: Tata McGraw Hill.
Company Profile, (2012), Indian Railways Database, Electric Railway Loco Shed,
Kazipet.
Cooper Donald, Pamela Shindler., (2010), Business Research Methods (11th edition),
New York: McGraw-Hill.
Jain, Khan, (2008), Cost Accounting, New Delhi: Tata McGraw Hill.
[69]