Semester Project
Materials
Management System
for Organizations
Material Management System
Prepared By:
Student Name: Mohammad Asif Khan
Student ID: MB-2-05-51271
Semester: Fall-2015
Campus: PAF-KIET (City Campus)
Material Management System
MaterialsManagement
Materialmanagementisanapproachfor
planning,organizing,andcontrollingall
thoseactivitiesprincipallyconcerned
withtheflowofmaterialsintoan
organization
Material Management System
Material Management System
Objectives:
ThefundamentalobjectivesoftheMaterialsManagement
function,oftencalledthefamous5RsofMaterials
Management,areacquisitionofmaterialsandservices:
•oftherightquality
•intherightquantity
•attherighttime
•fromtherightsource
•attherightprice
Material Management System
From the management point of view , the key
objectives of Material Management are :
•Tobuyatthelowestprice,consistentwithdesiredquality
andservice
•Tomaintainahighinventoryturnover,byreducingexcess
storage,carryingcostsandinventorylossesoccurringdue
todeteriorations,obsolescenceandpilferage
•Tomaintaincontinuityofsupply,preventinginterruption
oftheflowofmaterialsandservicestousers
•Tomaintainthespecifiedmaterialqualitylevelanda
consistencyofqualitywhichpermitsefficientandeffective
operation.
Material Management System
•Todevelopreliablealternatesourcesofsupplyto
promoteacompetitiveatmosphereinperformanceand
pricing
•Tominimizetheoverallcostofacquisitionby
improvingtheefficiencyofoperationsandprocedures
•Tohire,develop,motivateandtrainpersonnelandto
provideareservoiroftalent
Material Management System
•Todevelopandmaintaingoodsupplierrelationships
inordertocreateasupplierattitudeanddesirefurnish
theorganizationwithnewideas,products,andbetter
pricesandservice
•Toachieveahighdegreeofcooperationand
coordinationwithuserdepartments
•Tomaintaingoodrecordsandcontrolsthatprovidean
audittrailandensureefficiencyandhonesty
•ToparticipateinMakeorBuydecisions
Material Management System
Scope of Materials Management:
Basically, under its scope are :
•emphasis onthe acquisition aspect
•inventory control and stores management
•material logistics, movement control and handling
aspect
•purchasing, supply , transportation , materials
handling etc
•supply management or logistics management
•all the interrelated activities concerned with materials
Material Management System
Sub Functions of Material Management:
Thebroadmaterialsfunctionhasthefollowingas
identifiedandinterlinkedsubfunctions:
•Materials planning and control:
•Purchasing:
•.Stores:
•Inventory control:
Material Management System
Material Management System
PROCEDURE FOR MATERIAL
PROCURMENT AND USE:
Althoughproductionprocessesandmaterials
requirementsvaryaccordingtothesizeandtypeof
industry,thecycleofprocurementanduseofmaterials
usuallyinvolvesthefollowingsteps:
Material Management System
PROCEDURE FOR MATERIAL
PROCURMENT AND USE
•Engineering, Planning and Routing:
•The Production Budget:
•The Purchase Requisition:
•The Purchase Order:
•The Receiving Report:
•The Materials Requisitions:
•The Material Ledger Cards:
Material Management System
PROCEDURE FOR MATERIAL PROCURMENT AND
USE:
Material Management System
PURCHASES OF PRODUCTIVE MATERIALS:
POURCHASE DEPARTMENT:
The purchasing department is responsible to:
•Receive purchase requisitions for materials, supplies,
and equipment;
•Keep informed concerning sources of supply, prices
and shipping and delivery schedules;
•Prepare and place purchase orders, and
•Arrange the purchasing, the receiving, and the
accounting departments.
Material Management System
PURCHASES OF PRODUCTIVE MATERIALS
Purchasing Forms
PurchaseRequisition:
Thepurchaserequisitionoriginateswith:
•Astoresorwarehouseclerk,whoobservesthatthe
quantityonhandisatasetorderingminimum,
•Amaterialsledgerclerk,whomayberesponsiblefor
notifyingthepurchasingagentwhentobuy,
Material Management System
•A works manager, who foresees the need for
materials or unusual quantities
•A research, engineering or other department
employee or supervisor who needs materials or
supplies of special nature, or
•An information system that has been installed or
developed to produce replenishment advice for the
purchasing department.
•Onecopyremainswiththeoriginator,andthe
originalissenttothepurchasingdepartment.
Material Management System
Thepurchaseorder,signedbyisawritten
authorizationtoavendortosupplyspecifiedquantities
ofdescribedgoodsatagreedtermsandatdesignated
timeandplace.
Thepurchaseordergivesthevendoracomplete
descriptionofthegoodsandservicesdescribedthe
terms,theprices,andtheshippinginstructions.
Purchase Order:
Material Management System
Specimen of Purchase Order
Material Management System
Receiving:
The fundamentals of the receiving department
are to:
•Unload and unpack incoming materials,
•Check quantities received against the shipper’s
packing list,
•Identifying goods received with descriptions on the
purchase order,
Material Management System
Receiving:
•Notifying the purchasing department of
discrepancies disco…….,
•Arrange for inspection when necessary,
•Notifying the traffic department and the
purchasing department of any damage in transit,
and
•Route accepted materials to the appropriate
factory location.
Material Management System
•Receiving:•Receiving:
Specimen of Receiving
Material Management System
ISSUING AND COSTING OF MATERIALS
Tocontrolthequantityandcostofmaterials,supplies,and
servicesrequiresasystematicandefficientsystemof
purchasing,recording,andstoring.Equallynecessaryisa
systematicandefficientprocedureforissuingmaterials
andsupplies.
Material Management System
ISSUING AND COSTING OF MATERIALS
Material Requisition:
Thematerialsrequisitionisawrittenordertothe
storekeepertodelivermaterialsorsuppliestothe
placedesignatedortogivethematerialstothe
personpresentingaproperlyexecutedrequisition.
Material Management System
SPECIMEN OF MATERIAL REQUISITION
Material Management System
ISSUING AND COSTING OF MATERIALS
Material Requisition Journals:
MaterialRequisitionedJournalisnecessarytopost
thematerialswithdrawalsfromthestore.Thejournal
isformofmaterialssummary.Attheendofthe
month,thetotalsofthevariouscolumnsareposted
directlytotheledgeraccounts.
Material Management System
ISSUING AND COSTING OF MATERIALS
Bill of Materials:
The bill materials, a kind of master requisition, are a
printed or duplicated form that lists all materials and
parts necessary for a typical job or production run.
Time is saved and efficiency is promoted through the
use of a bill of materials. When a job or production
run is started, all the materials listed on the bill of
materials are sent to the factory are issued on a pre
arranged time schedule.
Material Management System
ISSUING AND COSTING OF MATERIALS
Just-In-TimeInventoryProcedures:
Manufacturingprocessesareincreasinglybeingbased
onthereceiptofrawmaterialsfromsuppliers“Just-In-
Time”fortheiruseontheplantfloor.
Whenafirm’srawmaterialscanbehandledinthis
immediateusemode,thetraditionalstoreroom,
receipt,storageandissuanceproceduresare
abbreviated.Storage,exceptforbriefperiodsdirectly
ontheplantflooriseliminated.Receiptandissuing
documentationcanbecombined.Asaresult,thereis
savinginpaperworkand,moreimportantlyasavings
ininventoryinvestment,storageandhandling.
Material Management System
ISSUING AND COSTING OF MATERIALS
MaterialLedgerCard:
PerpetualInventory:
Inperpetualinventorysystem,anentryismadeeach
timetheinventoryisincreasedorreduced.
Materialsledgercardsorstockledgersheetsconstitute
asubsidiarymaterialsledgercontrolledbythe
materialsorinventoryaccountsinthegeneralledger.
Materialsledgercardscommonlyshowtheaccount
number,descriptionortypeofmaterial,location,unit
measurement,andmaximumandminimumquantities
tocarry.
Material Management System
ISSUING AND COSTING OF MATERIALS
PhysicalInventory:
Thealternativetoaperpetualinventorysystemistheperiodic
inventorysystem,wherebypurchasesareaddedtothe
beginninginventory,theending(remaining)inventoryis
consideredthecostofmaterialissued.
Regardlessofwhetheraperiodicoraperpetualinventory
systemisused,periodicphysicalcountsarenecessaryto
discoverandeliminatediscrepanciesbetweentheactual
countandthebalancesonmaterialsledgercards.
Thesediscrepanciesmaybeduetoerrorsintransferring
invoicedatatothecards,mistakesincostingrequisitions,
unrecordedinvoicesorrequisitionsorspoilage,breakageand
theft.
Material Management System
ISSUING AND COSTING OF MATERIALS
Specimen of Material Ledger Card
Material Management System
MATERIAL COSTING METHODS
Theultimateobjectiveofmaterialmanagementisto
produceaccurateandmeaningfulfiguresofthecost
ofgoodssoldforcostaccounting.
Thefigurescanbeusedforpurposeofcontroland
analysisandareeventuallymatchedagainstrevenue
producedinordertodetermineoperatingincome.
Themorecommonmethodsofcostingmaterials
revenueproducedinordertodetermineoperating
income.
Material Management System
MATERIAL COSTING METHODS
Themorecommonmethodsofcostingmaterials
issuedandinventoriesare:
•First-In-First-Out (FIFO)
•Average Costing
•Last-In-First-Out (LIFO)
•Other Methods-such as
oMarket Price at date issue, or Last purchase price,
oStandard Cost
Material Management System
MATERIAL COSTING METHODS
First-In-First-Out(FIFO)MethodofCosting:
TheFIFOmethodisrecommendedwhenever:
•Thesizeandcostofmaterialsunitsarelarge,
•Materialsareeasilyidentifiedasbelongingtoa
particularpurchasedlot,and
•Notmorethanhowtwoorthreedifferentreceiptsof
thematerialsareonamaterialscardatonetime.
Material Management System
MATERIAL COSTING METHODS
First-In-First-Out(FIFO)MethodofCosting:
Material Management System
MATERIAL COSTING METHODS
AverageCostingMethod:
Issuingmaterialsatanaveragecostassumesthateach
batchtakenfromthestoreroomiscomposedofuniform
quantitiesfromeachshipmentinstockatthedateofissue.
Averagecostingmaybeusedeventhoughthephysical
withdrawalisinanidentifiableorder.Ifmaterialstendtobe
madeupofnumeroussmallitemslowinunitcostand
especiallyifpricesaresubjecttofrequentchange,average
costingisadvantageousbecause:
Material Management System
MATERIAL COSTING METHODS
AverageCostingMethod:
•Itisrealisticcostingmethodtomanagementin
analyzingoperatingresultsandappraisingfuture
production.
•Itminimizestheeffectofunusuallyhighormore
stablecostestimatesforfuturework.
•Itisapracticalandlessexpensiveperpetual
inventorysystem.
Material Management System
MATERIAL COSTING METHODS
AverageCostingMethod:
Material Management System
MATERIAL COSTING METHODS
Last-In-First-Out(LIFO)MethodofCosting:
Thelast-in-first-out(LIFO)methodofcostingmaterials
issuedisbasedonthepromisethatmaterialsunits
issuedshouldcarrythecostofthemostrecent
purchase,althoughthephysicalflowmayactuallybe
different.Themethodassumesthatthemostrecent
cost(theapproximatecosttoreplacetheconsumed
units)ismostsignificantinmatchingcostwith
revenueintheincomedeterminationprocess.
Material Management System
MATERIAL COSTING METHODS
Last-In-First-Out(LIFO)MethodofCosting:
Material Management System
MATERIAL COSTING METHODS
Other Materials Costing Method:
Besides LIFO, FIFO & Average Cost methods of
costing materials units into work in process, various
other methods exist:
•Market Price at Date of Issue or Last Purchase
Price:
•Standard Cost:
Material Management System
MATERIAL COSTING METHODS
•Market Price at Date of Issue or Last Purchase
Price:
Materials precisely standardized and traded on
commodity exchanges such as cotton, wheat, copper,
or crude oil, are sometimes costedin to production at
the quoted price at the date of issue. In effect, this
production substitute replacement cost for experienced
or consumed cost and has the virtue of changing
materials into production at a correct and significant
cost.
Material Management System
MATERIAL COSTING METHODS
StandardCost:
Thismethodchangeissuedmaterialsata
predeterminedorestimatedcostreflectinganormalor
isexpectedfuturecost.Receiptsandissuesof
materialsarerecordedinquantitiesonlyonthe
materialsledgercardsorinthecomputerdatabank,
therebysimplifyingtherecordkeepingandreducing
clericalordataprocessingcosts.
Material Management System
MATERIAL PLANNING AND CONTROL
Aninventoryplanningandcontrolmethodshould
havebutonegoalthatmightbeexpressedintwo
ways:
•Tominimizetotalcost,or
•Tomaximizeprofitwithinspecifiedtimeand
resourceallocations.
Material Management System
MATERIAL PLANNING AND CONTROL
PlanningMaterialsRequirements:
Toplanmanufacturingrequirements,everystockitemor
classofitemsmustbeanalyzedperiodicallyto:
•Forecast demand for the next month, quarter, or year.
•Determine acquisition lead time.
•Plan usage during the lead time.
•Establish quantity on hand.
•Place units on order.
•Determine reserves or safety stock requirements.
Material Management System
MATERIAL PLANNING AND CONTROL
MaterialsControl:
Thecontrolofmaterialsmustmeettwoopposingneeds:
•Maintenanceofaninventoryofsufficientsizeand
diversityforefficientoperations,and
•Maintenanceofafinanciallyfavorableinventory.
Material Management System
MATERIAL PLANNING AND CONTROL
MaterialsControlObjectives:
Abasicobjectiveofmaterialscontrolistheabilityto
placeanorderattheappropriatetimethebestsource
toacquiretheproperquantityattherightpriceand
quality.Effectiveinventorycontrolshould:
•Provideasupplyofrequiredmaterialsandparts
forefficientanduninterruptedoperations.
•Provideamplestockinperiodsofshortsupply
(seasonal,cyclical,orstrike),andanticipateprice
changes.
Material Management System
MATERIAL PLANNING AND CONTROL
•Storematerialswithaminimumofhandlingtime
acostandprotectthemfromlossbyfire,theft
elementsanddamagethroughhandling.
•Keepinactive,surplus,andobsoleteitemstoa
minimumbysystematicreportingofproduct
changeswhichaffectmaterialsandparts.
•Assureadequateinventoryforpromptdeliveryto
customers.
•Maintaintheaccountofcapitalinvestedin
inventoriesatalevelconsistwithoperating
requirementsandmanagement’splans.
Material Management System
MATERIAL PLANNING AND CONTROL
•Control Principles:
Inventory control systems and techniques should be
based on the following principles:
•Inventoryiscreatedbypurchasing:
oMaterialsandparts,and
oAdditionallaborandoverheadtoprocessthe
materialsintofinishedgoods.
•Inventoryisreducedthroughsalesandspoilage.
•Accuratesalesandproductionscheduleforecastsare
essentialforefficientpurchasing,handling,and
materialsinvestment.
Material Management System
MATERIAL PLANNING AND CONTROL
•Control Principles:
•Management policies, which attempt to balance size and
diversity of inventory, are the greatest factor in
determining inventory investment.
•Ordering materials is a response to forecasts, scheduling
production controls inventory.
•Inventory records alone do not achieve inventory control.
•Control is comparative and relative, not absolute. It is
exercised by people with varying experience and
judgment.
•Rules and procedures guide these individuals in making
evaluations and decisions.
Material Management System
•Warehousing
•Packing
•Traffic
•Shipping
•Statistical Analysis
MATERIAL PLANNING AND CONTROL
Organizing for Materials Control:
A materials management department may include
some or all of the following sections:
•Planning and
Scheduling
•Purchasing
•Receiving
•Inspection
•Stores
•Materials Handling
Material Management System
MATERIAL PLANNING AND CONTROL
Material Control Methods:
Materials control methods differ primarily in the care
and cost expanded. Critical items and high-value items
require greater attention than do low-value items.
Control methods include the:
•Order cycling,
•The min-max, and
•Just-in-time
Material Management System
MATERIAL PLANNING AND CONTROL
OrderCyclingMethodorCyclingReviewMethod:
Thismethodexaminesperiodically(e.g.each30,60,or90
days)thestatusofquantitiesonhandofeachitemorclass.
Differentcompaniesusedifferenttimeperiodsbetween
reviewsandmayusedifferentcyclesfordifferenttypesof
materials.Highvalueitemsandthatwouldtieupnormal
operationsifoutofstockusuallyrequireashortreviewcycle.
Onlow-costandnoncriticalitems,alongerreviewcycleis
common,sincethesematerialswouldbeorderedinlarge
quantitiesandstockoutwouldnotbeascostly.
Material Management System
MATERIAL PLANNING AND CONTROL
Min-MaxMaterials:
Thismethodisbasedontimepremisethatthe
quantitiesofmoststockitemsaresubjecttodefinable
limits.Amaximumquantityforeachitemis
established.Aminimumlevelprovidesthemarginof
safetynecessarytopreventstockoutsduringa
recordercycle.Theminimumlevelsetstheorder
point,andthequantitytoorderwillusuallybring
inventorytothemaximumlevel.
Material Management System
MATERIAL PLANNING AND CONTROL
Just-in-TimeMaterialsControl:
Thesavingthatcanresultfromaminimuminventoryinvestment
andassociatedcarryingcostshasledtoincreasingattentiontoa
just-in-time(JIT)system.Suchaprocedurecallsforheightened
coordinationwithsupplierssothatmaterialsarriveimmediately
priortotheiruse.
Japaneseindustryiscreditedwithpioneeringthisprocedurethat
isnowbeingusedbysomeU.S.manufacturers.Forexample,
GeneralMotorshasimplementedthisapproach,withafully
automatedJITpartsinventorysystem.
Material Management System
MATERIAL PLANNING AND CONTROL
SelectiveControl:
TheABCPlan:
Segregationofmaterialsforselectivecontrolcalled
theABCplanisananalyticalapproachbasedupon
statisticalaverages.TheABCPlan,measuresthecost
significanceofeachmaterialsitem.
•A”orHighValue,itemswouldbeunderthetightestcontrol
andtheresponsibilityofthemostexperiencedpersonnel
•“B”orMedium-Value,itemswouldunderthelessstrict
controlascomparetoA.
•“C”orLow-Value,itemswouldbeundersimplephysical
controls,suchasthebin-systemwithsafetystocks.
Material Management System
CONTROLLING MATERIALS IN PROCESS
Workinprocessinventoryinvestmentislargelydeterminedby
thetimenecessaryforgoodstopassthroughtheproduction
process.Thetimeinvolvedincludes:
•Setuptime-preparingtorunajobonamachine.
•Runningtime-actuallyperformingthework.
•QueueTime-theamountoftimethatthejobspendswaiting
tobeworkedon.
•Movetime-transportingthegoodstothenextprocessing
location.
•Waittime-timespentwaitingtobemoved.
Material Management System
CONTROLLING MATERIALS IN
PROCESS
ControllingFinishedGoods:
Anaccuratesalesforecastisthekeytoeffectively
managingfinishedgoodsinventoriesandmeetingdelivery
dates.Thisforecastmustbecommunicatedtoproduction
controldepartmentsinordertodevelopproduction
schedulesformeetingsalescommitments.
Tomeetcustomerperformancesandcompetition,
manyproductlinesfeatureagrowingarrayofcolors,
sizes,andoptionalequipment.Thisresultsinadded
finishedgoodsinventoryitemsandmoreworkin
processinventory.Theneedfortightercontrol
becomesincreasinglyimportant.
Material Management System
CONTROLLING MATERIALS IN PROCESS
ControlofObsoleteandSurplusInventory:
Almosteveryorganizationisfacedwiththeproblemof
surplusandobsoleteinventoryatonetimeorother.
Whateverthemanypossiblereasonsforsuchconditions,
someactionisrequiredinordertoreduceoreliminate
theseitemsfrominventoryandfreetherelatedcapital.
Toaccomplishareduction,managementshouldfirst
makecertainthatthebuildupwillnotcontinuedueto
presentorderingpolicies,andshouldthentakestepsto
disposeofstock.
Material Management System
CONTROLLING MATERIALS IN PROCESS
ControlofObsoleteandSurplusInventory:
Accurateperpetualinventoryrecordsshowingacquisitions
andissuequantitiesanddates,aswellasperiodicreviewof
therecords,arenecessarytoidentifyobsoleteandsurplus
items.
Obsoleteinventoryusuallyresultsfromchangingadesign
ordroppingaproduct.Promptsaleoftheinventoryforthe
firstreasonableofferinoftenthebestpolicy.
.
Material Management System
CONTROLLING MATERIALS IN PROCESS
ReportingonInventoryControl:
Managementrequirestimelyinformationconcerning
inventorycontrolefforts.Thisinformationshouldbe
reportedinaconcise,easilyunderstoodform.
Quantitativeaswellasgraphiccomparisonsofactual
andbudgetedinventoryusetoreportinventorytrend
withintheorganization.
.
Material Management System
THEIMPACTOFMODERNIZER FACTORY
PROCESSESONMATERIALMANAGEMENT
Ininventorynumbers,factoriesaremovingfrom
manufacturingprocessesinvolvingmanualand/or
fixedautomatedsystems.Theshiftistowardflexible
manufacturingsystem,whichconsistofanintegrated
collectionofautomatedproductionprocesses,
automatedmaterialsmovement,andcomputerized
systemcontrolstoutilizethefacilitiesintheefficient
manufactureofahighlyflexiblevarietyofproducts.
Theextentofproductvarietyisconstrainedbythe
needfortheproductstosharecertainbroad
characteristicsthatallowgroupingwithinaparticular
familyofproductswhilemaintainingconsiderable
flexibility.
Material Management System
THE IMPACT OF MODERNIZER
FACTORY PROCESSES ON
MATERIAL MANAGEMENT
Flexiblemanufacturingsystemsimpactuponand
altermanyofthefactorsthatmanagementshould
considerinevaluatingasystem,especiallythe
planningandcontrolofrawmaterialsandworkin
processinventories.Theaffectofeachsystem-
manual,fixedautomationandflexible
manufacturing–onthesefactorsissummarizingas
follows:
Material Management System
FACTORS
MANUAL
SYSTEMS
FIXED
AUTOMATION
SYSTEMS
FLESIBLE
MANUFACTUR
ING SYSTEMS
NumberofKindsofProducts Many Only one Several
Viableproductionvolumes Low High Middle
ProductQuality Varies Tightly Consistent
Setuptimes High Very High Short
LearningCurveEffect SubstantialDepends on
Degree of
Automation
None
LearningTimes(PerUnit)tosupplycustomer
demands
Usually HighModerate Moderately
Low
DirectLaborCostTotal/PerUnit High Low Very Low
InventoriesMaterialsworkinProcess High High High
MachineUtilization Low High High
SpaceRequisition Extensive ExtensiveModerate
CapitalCost Low High High
Sensitivitytoeffectsofbreakdownofsingle
machineorgroupofmachines
Low High High
Responsivenesstochangeindemand High Low High
Material Management System
EDP (Electronic Data Processing) For
Material Management:
Theprecedingdescriptionsofinvoiceapprovaland
paymentwereformanualoperationsperformedbyan
accountspayableclerkoraninvoiceclerk.
Inanelectronicdataprocessing(EDP)system,the
computer-toagreatextent-replacestheclerk.Upon
receiptoftheinvoice(thesourcedocument),the
accountspayableclerkenterstheaccountdistribution
ontheinvoice.Thedataarethendirectlyinputted
fromtheinvoicetothecomputerdatabankviaa
terminaldevice.Thedataareedited,audited,and
mergedwiththepurchaseorderandthereceiving
orderdata,bothofwhichhavebeenstoredinthe
computerdatabank.
Material Management System
EDP (Electronic Data Processing) For
Material Management:
Thecommonmatchingcriteriononalldocumentsis
thepurchaseasalldocumentsisthepurchaseorder
number.Quantities,monetaryvalues(amounts),due
dates,termsandunitpricesarematched.Whenin
agreement,thecostdataareenteredintheaccounts
payablecomputerfilewithadateforlaterpayment,
oraprintoutofacheckistransmittedforpayment.
Listingsinjournalformcanbeproducedasneeded.
Material Management System
EDP (Electronic Data Processing) For
Material Management:
Theaboveproceedaredealswiththeaccountspayable
phaseofapurchasetransactionofequalimportanceisthe
needforpostingthedatainquantitiesandamountstothe
materialsinventoryfileintheEDPsystem.Theinformation
enterstheEDPsystemfromeithertheinvoiceortheinvoice
ortheinvoiceapprovalfrom,whichwouldhavetoinclude
allcomputernecessarydata.Theinternalcomputerprogram
updatesthematerialsinventoryfile.Thewithdrawalof
materialscouldalsobecomputerized,sothatmanual
postingstothematerialsinventoryfile,aswellasother
manualoperations,wouldbeeliminated.