Beruflich Dokumente
Kultur Dokumente
Declaration
This is to declare that the Report entitled WORKING CAPITAL AND INVENTORY MANAGEMENT IN TATA STEEL has been made for the partial fulfillment of the Course: Summer Internship Program (SIP) by me at TATA STEEL LTD. under the guidance of Prof.L.Narsimham Pappu. I confirm that this Report truly represents my work undertaken as a part of my Summer Internship Program (SIP). This work is not a replication of work done previously by any other person. I also confirm that the contents of the report and the views contained therein have been discussed and deliberated with the Faculty Guide.
: : Shailaja S : 11BSPHH010746
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ACKNOWLEDGEMENT
The fundamental characteristic of the summer internship Program lies not just in the successful completion of a given assignment but also in the positive expansion of the professional business person inside the student who undertakes such an assignment. I would like to pay my gratitude to the following people for guiding me throughout my association with them. I would like to extend my gratitude to Mr. Indrajit Roy (Head Financial Accounts) for giving me opportunity to work in such an important sphere and for sharing his vision and experience. Mr. Imtiaz Ahmed for his continuous support and guidance; Mr. G. Ghosh (Manager, Management Development TMDC) for providing me the opportunity to learn and complete my summer internship in this esteemed organization I also take the opportunity to thank Prof. L. Narsimham Pappu (IBS Hyderabad) for his guidance and invaluable inputs in the development of the project, and in terms of managing the real time issues that we faced in the corporate world. Last but not the least I would like to extend my thanks to all the employees at Finance department, my family and friends for their cooperation, valuable information and feedback during my project.
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Executive Summary
Inventories are the most integral part of the current assets of an organization. Management of inventories is important because it has a direct impact on the financial resources of the organization. Excess investment in inventories is not good because the funds will then be held up in inventories and will not be available for other important uses. Less investment is also detrimental because the company might be incapable of fulfilling the demand for its products. Therefore, proper inventory management is very essential for an organization. The project explains in detail the concepts of inventory management which serves as a platform for the study conducted. Various ratios have been taken out on the basis of the data so as to find out the trends of inventory management in Tata Steel. A brief study of the Indian steel industry has also been conducted so as to carry out a comparative analysis of Tata Steel with two other major players namely SAIL and Jindal Steel Works. This analysis studies the different techniques used by different companies, and the effectiveness of these. A company of Tata Steels stature is expected to have a good management of its Working Capital. Working Capital of a company is the difference between its current assets and the current liabilities. It includes the companys debtors, bank/cash, creditors, inventory, outstanding and other miscellaneous expenses. Each of these needs to be managed separately so as to have a control over the liquidity of business. Management of Working Capital includes various IBS HYDERABAD sub-components Page 3
at the operational level of the company which directly affect the level of Working Capital. These include study of Letter of Credit, Bill Discounting, Factoring through Receivable Purchases, Channel Financing, and Overdraft management. Proper Working Capital Management depends on how well these sub-components are handled. The company needs to overcome the shortcomings in this respect.
CHAPTER-1
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Steel Industry is becoming more and more competitive with every passing day. During the period of 1960s to late 1980s, the steel market used to be dominated by OECD (Organization for Economic Cooperation and Development) countries. But with the fast emergence of developing countries like China, India and South Korea in this sector has led to slipping market share of OECD countries. The balance of trade line is also tilting towards these countries. World crude steel production for the 59 countries reporting to the World Steel Association (world steel) was 119 million tonnes (Mt) in February 2012. This is 1.9% higher than February 2011. The main demand for World Steel Industries comes from the construction industry. With the developmental works on a rise in both the developed and developing countries, the infrastructure industry along with real estate boom, the demand for steel is rising like anything. For example, more and more real estate companies are using steel frames for building houses. In USA, it had been observed in the early 90s that the use of steel for house building has increased by nearly five times in just one year. The automobile industry is also coming up fast as a potential demander for World Steel Industries because through research it has been found out that the use of steel in the vehicles would cause the weight of the same to lessen by almost twenty five per cent. The other industries who demand steel involve appliance industries, Oil and Gas industries and container industries. On the technological front, the World Steel Industries are making rapid improvement with the implementation of cutting-edge technologies like steel making through the utilization of electric furnace, continuous annealing, casting of thin slabs, and vacuum degassing. The global steel industry is highly cyclical, very competitive and still fragmented in terms of market share. Currently the industry is at the height of the business cycle and is going through a consolidation phase, which might result in the smaller players being acquired by the larger ones. The steel industry demonstrates a high degree of variability, both in terms of earnings and production. The factors attributable for driving this variability are global economic conditions with a particular sensitivity to the performance of the automotive, construction, capital goods and other industrial products industries. The commodity nature of steel, the producers and consumers limited control on price, and the demand & supply disparity have made steel prices volatile. Significant increases in prices for metals and energy over the past two years have also contributed to increased variability in the industry. IBS HYDERABAD Page 6
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The global steel industry is highly cyclical, very competitive and still fragmented in terms of market share. Currently the industry is at the height of the business cycle and is going through a consolidation phase, which might result in the smaller players being acquired by the larger ones. The steel industry demonstrates a high degree of variability, both in terms of earnings and production. The factors attributable for driving this variability are global economic conditions with a particular sensitivity to the performance of the automotive, construction, capital goods and other industrial products industries. The commodity nature of steel, the producers and consumers limited control on price, and the demand & supply disparity have made steel prices volatile. Significant increases in prices for metals and energy over the past two years have also contributed to increased variability in the industry.
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The size of India's steel industry has increased considerably in recent years. As of 2011,India occupies the 5th position in the world in steel production at 72.2 million tonnes and has huge potential for growth as Indias per capita steel consumption is far world standards. The steel industry of India has capital investments of more than Rs 100, 000 crores. The total employment in the industry is more than two million (including direct and indirect employment) and it has been assessed that, on a most likely scenario basis, crude steel production capacity in the country by the year 2012-13 will be nearly 110 million tonne. Also, the Indias consumption of stainless steel is much higher at 14% as compared to the global consumption of 6% in the last 10 years. lower compared to China and
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Ministry of Steel has initiated the process of drafting the New National Steel Policy in place of existing National Steel Policy of 2005 in order to discourage export. According to Beni Prasad Verma, India Minister for Steel, India has become a net importer of steel from 2007-08 due to high growth in steel consumption relative to production.
Some of the major reasons that have led to the growth in the size of Indian steel Availability of iron-ore in abundance in India Facilities for steel production available are favourable to producers.
industry are:-
Increased consumption of steel in the sectors like construction, automobile and infrastructure.
Steel Industry
Steel is an important indicator to analyze the economic development of a country. The steel industry is highly scientific and technology oriented. Technological advancement is very important for the overall health of the steel industry.
During Ancient Period The history of iron and steel making in India goes back by several centuries. It dates to 480 BC when archers in India used arrows tipped with steel. The iron pillar of Dhar near Indore in Madhya Pradesh dates back to about 321 AD, the iron pillar of Qutub Minar near Delhi dates back to about 400 AD and the iron beams of Sun temple of Konark in Orissa dates back to 13th century. These pillars are a testimony to ancient India's expertise in the making of steel. Before Independence The roots of the Indian Steel industry in modern times can be traced to the year 1874, when a company called Bengal Iron works at Kulti near Asansol in West Bengal produced iron. One of the most important landmarks in the history of Indian steel industry was the commencement of the IBS HYDERABAD Page 10
Tata Iron and Steel Company at Jamshedpur in the state of Bihar in 1907.The other prominent steel manufacturers before independence were Indian Iron and Steel Company (1922), Mysore Iron and Steel Works(1923) and Steel Corporation of Bengal (1937). After Independence India found it very difficult to sustain development in steel sector after independence on its own due to the lack of technological development. The high cost of developing technology in this sector proved to be a major hindrance. That's when the government decided to go for synergy with other countries for technology transfer. Some of the prominent steel plant set up then was in Rourkela in collaboration with West Germany and in Bokaro in collaboration with Russia. These steel plants came under the purview of public sector enterprises. Post Liberalization The post liberalization scenario in the Indian Steel industry has witnessed a monumental shift. Some of the salient features are:
The need for license for increasing capacity has been abolished. Steel industry has been removed from the list of Industries under the control of state sector. Foreign equity investment in steel has gone up to 74%. In January 1992 the price and distribution controls were removed. Policies like convertibility of rupee on trade account, freedom to mobilize resources from overseas financial markets and restructuring of existing tax structure have immensely benefited the industry.
Milestone The Indian steel industry has come a long way since its humble beginnings. The takeover of the British steel giant, Corus steel by Tata Steel and the acquisition of Arcelor by Mittal Steel herald a new beginning for the Indian steel industry. These events signify the fact that the Indian steel industry has acquired a global identity and are today extremely competitive globally. Some of the prominent steel producers today are Posco, Tata Steel, Essar, Ispat, Sail and Rinl. Future trends IBS HYDERABAD Page 11
It has to be said that the global recession has affected the Indian steel industry especially stainless steel, but the steel industry is trying to offset the negative effect of the recession by focusing on transportation and construction projects which are usually funded by the government.
India is the only country globally to record a positive overall growth in crude steel production at 1.01 per cent for the period January -March 2009. It is estimated that India's steel consumption will grow at nearly 16% annually till 2012. The National Steel Policy has forecasted the demand for steel would reach 110 million tons by 2019-2020. Industry Statistics Government targets to increase the production capacity from 56 million tonnes annually to 124 MT in the first phase which will come to an end by 2011 - 12. Currently with a production of 56 million tones India accounts for over 7% of the total steel produced globally, while it accounts to about 5% of global steel consumption. The steel sector in India grew by 5.3% in May 2009. Globally India is the only country to post a positive overall growth in the production of crude steel at 1.01% for the period of January - March in 2009.
Some of the major reasons that have led to the growth in the size of India's steel industry a. Abundant availability of iron-ore in India. b. Good facilities for steel production.
c. Increased consumption of steel in the sectors like construction, automobile and
infrastructure.
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COMPETITION ANALYSIS
Concentration Ratio:
In Economics the concentration ratio of an industry is used as an indicator of the relative size of firms in relation to the industry as a whole. This may also assist in determining the market form of the industry. One commonly used concentration ratio is the four-firm concentration ratio, which consists of the market share, as a percentage, of the four largest firms in the industry. In general, the N-firm concentration ratio is the percentage of market output generated by the N largest firms in the industry. The 4 firm concentration ratio of the Iron and Steel Industry is 71%. This implies that there is oligopoly in the industry as it is dominated my few major players. Major percentage of market output is generated by the 4 largest firms in the industry.
Herfindahl Index:
The Herfindahl index, also known as Herfindahl-Hirschman Index or HHI, is a measure of the size of firms in relationship to the industry and an indicator of the amount of competition among them. It is an economic concept but widely applied in competition law and antitrust. It is defined as the sum of the squares of the market shares of each individual firm. As such, it can range from 0 to 1 moving from a very large amount of very small firms to a single monopolistic producer. Decreases IBS HYDERABAD Page 14
in the Herfindahl index generally indicate a loss of pricing power and an increase in competition, whereas increases imply the opposite.
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Threat of new Entrants - The easier it is for new companies to enter the industry, the more cutthroat competition there will be. Steel industry is highly capital intensive and is estimated that to set up 1 MTPA capacity of integrated steel plant, it requires around Rs. 30 billion of investment depending upon the location of the plant and technology used. The government follows a favorable
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policy for steel manufacturers but certain discrepancies involved in allocation of iron ore mines and land acquisition in India. Bargaining power of suppliers - If one supplier has large impact on the companys margin and volume then it holds substantial power. In the steel industry the bargaining power of supplier is very low because the big players in the industry have their own mines for major raw materials. However, still a few companies have to depend up on suppliers for the raw materials. Bargaining power of buyers - In the steel industry unlike the household goods market the buyers have a very low bargaining power. The only effort which can be done towards ensuring that the buyers are saved in the curb or ceiling laid by the government on the prices which can be charged by the companies on its product. However, most of the sale of steel is to the other industries or to through the distribution network and very less to the common man. Competitive Rivalry - In India the steel industry is dominated by a major few players only and the degree of competitive rivalry is very low as the demand is always more than the supply or the production of the companies. Threats of substitutes - The presence of substitute products increases the propensity of customers to switch to alternatives. The usage of aluminum has been constantly growing in the automobile sector which used to be the major customer of the steel industry. However, because of the durability and other features of the steel, aluminum does not stand as a threat in the market.
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Weaknesses: High costs of some basic inputs like power, coal, fuel, etc. High social costs Poor quality of basic infrastructure Distribution network Low IT usage in efficiency enhancement Fragmentation
Opportunities: Low per capita consumption Unexplored rural market Low export market penetration
Threats:
Substitution by aluminum, plastic and composites one of the most remunerative Markets Automobiles
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Poor R&D and threat of technological obsolescence in a large part of the market Availability of imported low ash coking coal.
Costs and prices of different categories of iron and steel did not show any systematic relationship under dual pricing. A comparison of actual and calculated normated costs for each steel item revealed that only two items, i.e. heavy structural and H.R. coils, had been priced adequately. Some products, such as pig iron and semi-finished steel, were substantially under priced, others substantially overpriced. Since 1992 the government has gradually decontrolled prices and distribution of steel. The new policy still includes control over distribution to priority sectors. Private production, however, has been totally decontrolled. The levies charged by JPC for the Steel Development Fund, Engineering Goods Exports Assistance Fund and JPC Cess will continue. Yet, freight equalization has been abandoned subject to certain conditions. Furthermore import duties have been substantially reduced by 20% and more on imports of various semi-finished and finished steel products. In the progress of industrial development the government has also provided facilities to support mini-steel plants. These include (i) liberal import of melting scrap and sponge iron without import duty, (ii) free diversification into all grades of carbon and alloy steels, including stainless steel, (iii) installation of captive rolling units, (iv) addition of balancing facilities like continuous casting machines, heat treatment furnaces, etc.
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production grew by 60 million tonnes over 2006 (an increase of 14%). While Chinas production constitutes 34% of the world production, the countrys consumption constitutes almost 31% of the world consumption. The crude steel production in India was higher by 8% in 2007 over 2006. The increase primarily was due to a sustained demand momentum in key-end use segments like construction, capital goods and automobiles. The supply side has not been able to keep pace with the strong demand resulting in India becoming a net importer of steel. Steel production in the European Zone remained stable, with year-end figures of 210 million tonnes, a growth of around 2% over 2006. The imports in the European Union also remained at a high level during 2007. The latest global steel consumption forecast predicts 6.77% year on year increase in steel consumption in the current year. The additions in the capacity are likely to be around 90 million tonnes. The greatest concern of the steel industry is the availability of raw materials at a competitive price. There have been unprecedented cost increases in iron ore by around 65% and coking coal by around 200% in 2008, which would have an impact on the steel prices. Indian steel industry also experienced a strong growth in demand, propelled particularly by the demand for steel in China. The production of crude steel at 53 million tonnes in 2007 was more than double the production level a decade back in 1998 (23 million tonnes) portraying the significant growth in the Indian Steel Industry. India now ranks fifth in terms of crude steel production among the top six crude steel producing nations in the world, the others being China, Japan, United States, Russia and South Korea. The Finished Steel production in India in the current financial year stands at 48 million tonnes registering an increase of 9% over the previous year.
Indian government has been endeavoring to ensure that power is available nationwide by 2012. The deficiencies have prompted many firms with heavier energy demands to opt for producing electricity with their own industrial generators. India will rely squarely on nuclear energy for its future power generation requirements. In September 2005 the 15th IBS HYDERABAD Page 23
and largest nuclear reactor to date went on-line. The nuclear share of the energy mix is likely to rise to roughly 25% by 2050. Overall, India is likely to be the worlds fourth largest energy consumer by 2010 after the US, China and Japan.
Problems in procuring raw-material inputs - Since domestic raw material sources are
insufficient to supply the Indian steel industry; a considerable amount of raw materials has to be imported. For example, iron ore deposits are finite and there are problems in mining sufficient amounts of it. Indias hard coal deposits are of low quality. For this reason hard coal imports have increased in the last five years by a total of 40% to nearly 30 million tons. Almost half of this is coking coal (the remainder is power station coal). India is the worlds sixth biggest coal importer. The rising output of electric steel is also leading to a sharp increase in demand for steel scrap. Some 3.5 million tons of scrap have already been imported in 2006, compared with just 1 million tons in 2000. In the coming years imports are likely to continue to increase thanks to capacity increases.
infrastructure that has long been inadequate are becoming increasingly serious impediments to economic development. Although the country has one of the worlds biggest transport networks the rail network is twice as extensive as Chinas its poor quality hinders the efficient supply of goods. The story is roughly the same for port facilities and airports. In the coming years a total of USD 150 bn is to be invested in transport infrastructure, which offers huge potential for the steel industry. In the medium to long term this capital expenditure will lay the foundations for seamless freight transport.
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From the year 2002, the global steel industry grew with the steel demand shooting from 2% to 8% year on year. The Indian steel industry with its 43 million tonnes of steel production in a booming economy was also showing rapid growth. At such a time when the situation could not have been any better, in 2008 the global economic slowdown cast its shadow on almost all industries including steel. The steel industry was suddenly faced with a high locked up capital and is now having to resort to serious firefighting measures to overcome the current scenario. In the medium term the global steel industry is likely to undergo a more extensive process of consolidation since industry players are engaged in an unfettered rush for scale. In so doing steelmakers are pursuing two main objectives: by purchasing additional production capacity they aim to both improve their cost structure and increase their market clout. The merger of the worlds two biggest steelmakers Mittal Steel (Netherlands) and Arcelor (Luxembourg) will create an industry giant whose output is nearly four times as much as that of the next biggest player (Nippon Steel) and eight times as much as SAILs. In India the three biggest steelmakers, whose combined output is almost 20 million tonnes, have a market share of 51%. Their domestic competitors are numerous medium-sized and smallish companies. One of these, for example, is Ispat with an output of 2 million tonnes. More mergers can be expected between companies of this size as these firms need to improve their position with regard to the powerful suppliers of raw materials. Going forward, Indias lower wages and favourable energy prices will continue to promise substantial cost advantages compared to production facilities in (Western) Europe or the US. The growth prospects of the client industries are also very good. The deployment of modern production systems is increasingly enabling India to improve the quality of its steel products and thus to enhance its export prospects.
Company Profile
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Tata Steel formerly known as TISCO (Tata Iron & Steel Company) was established in 1907 by Mr. Jamshedji Nusserwanji Tata. Tata Steel has completed over 100 years of experience in steel making; it is a pioneer in steel industry in India. It is the Asias first integrated steel plant and now worlds second most diversified steel producer and a fortune 500 company. Tata Steel has been ranked at the top of the Nielsons corporate image monitor study followed by Tata Motors. The worlds most admirable companies 2011, published by fortune Magazine, ranks Tata Steel 6th in metal industry category. Tata Steel the worlds 5th largest steel company has an annual crude steel capacity of 30 mtpa (million tonnes per annum). It is the 2nd largest private sector steel company in India in terms of domestic production. It is a part of the Tata Group of Companies with consolidated turnover of 29396.35 crores during the year ended 31st march 2011. Its main plant is located in Jamshedpur. With its acquisition of the Corus, NatSteel and Millennium Steel it has become a multinational company with operations in various countries. Tata Steel has a balanced global presence in over 50 developed European and fast growing Asian markets, with manufacturing unit in 24 countries. It is the worlds second most geographically diversified steel producer. Also it is the worlds lowest cost producer of steel with shareholder base of 800,000 people and employee strength over 81,000 across 5 continents. With new industrial policy adopted by the Government of India has opened up the iron & steel sector for private investment by removing it from the list of industries reserved for public sector and exempting it from compulsory licensing. Imports of foreign technology as well as foreign direct investment are freely permitted up to certain limits under an automatic route. This, along with the other initiatives taken by the government has given a definite impetus for entry participation and growth of the private sector in the steel industry. While the existing units are being expanded, a large number of Greenfield steel plants have also come up in different parts of the country based on modern equipments, cost effectiveness and state of the art technologies.
Tata Steel is a business house that has created wealth for the nation. It is a story of struggle, adventure and achievement. The founder along with his successors is as follows: Jamshedji Nusserwanji Tata (1839-1904) Sir Dorabji Tata (1859-1933) Jehangir Ratanji Dadabhai (1904-1993) Ratan Naval Tata ( born 28th Dec193 till date)
SUBSIDERIES
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Jamshedpur Injection Powder Limited (Jamipol) JAMIPOL manufactures carbide de-sulphurising compounds which are used for de-sulphurising hot metal for the production of low-sulphur, high-quality steel. www.jamipol.com Jamshedpur Utility and Services Company Limited (JUSCO) Re-engineered out of Tata Steel's town services, JUSCO is a wholly owned subsidiary of Tata Steel and is the country's first enterprise that provides municipal and civic services for townships. JUSCO is the only EMS 14001 civic services provider in the country. www.juscoltd.com Lanka Special Steel Limited The only unit in Sri Lanka manufacturing galvanised wires. Rawmet Ferrous Industries Tata Steel acquired 100% equity stake in Rawmet Ferrous Industries on January 15, 2007. Currently, the Company is based out of Kolkata and operates as a subsidiary of Tata Steel. Rawmet has a Ferro Alloy Plant near Cuttack, with a capacity of 50,000 tonnes production per annum of High Carbon Ferro Chrome.
Sila Eastern Company Limited Established to develop limestone mines in Thailand, mainly for the captive use of Tata Steel.
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Tata Steel KZN Proposes to set up high carbon ferrochrome plant in South Africa. The plant is slated to be commissioned by October 2007 with an annual production capacity of 135,000 tonnes during Phase I.
Tata Metaliks Limited Tata Metaliks is recognised as Indias number one pig iron manufacturing and selling company. Promoted by Tata Steel Limited and assisted by The West Bengal Industrial Development Corporation, the pig iron produced by the Company is rated as the best in the country for years now. www.tatametaliks.com
TPL's range of products includes oxides of iron, dry cement paint, exterior emulsion paint and distemper. Its products are used in paints, emulsion, cement floors, plastic etc. www.tatapigments.com Tata Refractories Limited (TRL) It produces High Alumina, Basic, Dolomite, Silica and Monolithic Refractories and offers design, procurement and re-lining applications services. It is one of the few companies worldwide to produce silica refractories for coke ovens and the glass industry. The Company has a basic bricks manufacturing unit in China. www.tataref.com Tata Steel Processing and Distribution Limited (TSPDL)
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Tata Steel Processing and Distribution Limited is wholly owned subsidiary of Tata Steel. With 8 large processing units, 17 sales locations and a host of partners like external processing agencies, suppliers, retailers and other stakeholders, today TSPDL is Indias largest steel service organization. www.tspdl.com Tata Sponge Iron Limited (TSIL) TSIL is the first Indian sponge iron plant based on Tata Steel's Direct Reduction Technology. Its major product lines are sponge iron lumps and fines. www.tatasponge.com
Tayo Rolls Limited India's leading roll manufacturer and supplier, the company produces rolls which find application in integrated steel plants, power plants, the paper, textile and food processing sectors, and the government mint. www.tayo.co.in
Tinplate Company of India Limited (TCIL) With a market share of over 35%, it is the industry leader in India. It has the capability to supply all tinning line products including electrolytic tinplate / tin-free steel and cold-rolled products. www.tatatinplate.com
TRF Limited TRF, one of India's leading companies in the business of design, manufacture, supply, installation and commissioning of engineered-to-order equipment and systems in the areas of bulk material IBS HYDERABAD Page 30
handling, processing, reclaiming and blending. TRF has also made its mark in the fields of coke oven equipment, coal dust injection systems for blast furnaces and coal beneficiation systems. www.trfltd.com
Recently acquired by Tata Steel, ISWP has two units - a wire unit comprising wire drawing mills, wire rod mills and a fastener division and a steel roll manufacturing unit named Jamshedpur Engineering and Machining Company - JEMCO.
JOINT VENTURES
Dhamra Port Company, Orissa
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A JV between Larsen & Toubro Ltd. and Tata Steel Ltd., the company will build a deep draft (18 metres) all weather port on the east coast of India. The port will handle 80 million tonnes per annum of cargo. www.dhamraport.com
Mjunction, operating at the cutting edge of Information Technology, is a 50:50 venture of SAIL and Tata Steel. It is India's largest eCommerce company and the world's largest e-marketplace for steel. mjunction offers a wide range of selling, sourcing and knowledge services that empower businesses with greater process efficiencies. www.mjunction.in
Tata BlueScope Steel Limited A joint venture with BlueScope Steel Limited, Australia, Tata BlueScope Steel Limited offers a comprehensive range of branded steel products for building and construction applications. The Company is constructing a state-of-the-art metallic coating and painting facility at Jamshedpur. www.tatabluescopesteel.com
TM International Logistics Limited (TMILL) TMILL provides material handling and port operation services at Haldia and Paradip Ports in addition to providing freight forwarding and chartering services. www.tmilltd.com
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Tata NYK A joint venture with Nippon Yusen Kabushiki Kaisha (NYK Line) for setting up a shipping company to cater to dry bulk and break-bulk cargo. Tata Steel and NYK will each hold 50% stake in the joint venture company. www.tatanykshipping.com
S&T Mining Company Pvt Ltd Tata Steel imports about half of its coal requirements from overseas. As the countrys steel consumption enters a high and sustainable growth phase, the company is undertaking massive expansion plans. It has become imperative to ensure raw material security for the company. With this in mind, the company entered into a strategic alliance with the largest steel making company of India, SAIL. Accordingly, a new JV company, S&T Mining Co Private Limited was incorporated in September 2008 with its registered office in Kolkata. The Chairman of S&T Mining is Mr. S.N.Singh (Managing Director, Rourkela Steel Plant) while the MD of the company is Mr. Sandeep Kumar from Tata Steel.
PRODUCTS AT A GLANCE
Flat products: The Flat products business group of Steel division is the countrys largest manufacturer of world class steel products. With the capacity of 2.5 million tonnes per annum of hot rolled, cold rolled and coated products, this business group produces 65% of total IBS HYDERABAD Page 33
saleable steel. The steel with a soul, Tata Steelium is one of the first branded cold rolled steel products in India. The brand promises superior formability, flatness, surface quality, thickness, consistency and strength.
Long Products: The Long products business group of the Steel division produces value-added finished products comprising SBQ (Special Bar Quality), Wire rods, Merchant bars and semis in the form of continuous cast billets.
Ferro Alloys and Minerals: This business unit operates the chrome mines in Sukinda valley in Orissa and has a Ferrochrome making unit in Bamnipal and a Ferro-manganese unit in Joda. It is one of the largest players in global Ferro-chrome market.
Tubes: Tata Steel tubes business unit is the largest domestic manufacture of steel tubes. It promotes 3 lines of businesses: Standard tubes, Precision tubes and closed structural.
Bearings: Tata Steel produces around 22.46 million ball bearings and 2.56 million taper roller bearings.
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Growth Shop: Growth shop offers world class services and equipment. Over the years it has played an important role in modernization of Tata Steels Jamshedpur plant. The growth shop has the capacity to design, manufacture and commission equipment for the steel and allied industries.
Agrico: Tata Agrico products are the most sought after hand tools and implements for agriculture and industrial applications in the country.
CHAPTER-2
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RESEARCH METHODOLOGY
PRIMARY OBJECTIVE:
The main objective of the study is to put the theory into practice regarding the WORKING CAPITAL MANAGEMENT & INVENTORY MANAGEMENT at TATA STEEL Ltd.
SECONDARY OBJECTIVE:
To learn how companies like TATA STEEL Ltd manages its working capital resources.
1. 2. 3.
To understand the different components of working capital & inventory management. To have the in depth knowledge about Working Capital calculations and its interpretations. To analyze and find out the reasons as to what brings changes in working capital and inventory management for TATA STEEL Ltd. To understand the strategy adopted by TATA STEEL Ltd to manage its working capital in comparison with that of other companies over the years. To know the overall position of TATA STEEL Ltd in the steel industry in respect of working capital and inventory management.
4.
5.
SUGGESTIVE OBJECTIVE:
To offer suggestions and recommendations based on the study undertaken.
Type of research:
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The project is based on descriptive and applied research. Various inventory handling departments and techniques of inventory management have been explained in detail.
2.
Secondary sources: Annual reports Company website Other journals and books
Presentation of data:
Data collected from different sources have been presented in the following ways:
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The study is limited to the scope of the data available publicly. Ratio Analysis cannot be taken as the same indicator of the financial performance and growth of the company.
The study is based on the comparison across companies in the steel industry. However, the choice of different accounting policies and practices followed by these companies might distort the comparative analysis.
The study is based on a very short time frame which may have impact on the scope of the project in terms of the detailed analysis of the aspects of working capital management, the topic being wide.
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CHAPTER-3
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Every business needs funds for two purposes for its establishment and to carry out its day- to-day operations. Long terms funds are required to create production facilities through purchase of fixed assets such as p&m, land, building, furniture, etc. Investments in these assets represent that part of firms capital which is blocked on permanent or fixed basis and is called fixed capital. Funds are also needed for short-term purposes for the purchase of raw material, payment of wages and other day to- day expenses etc. These funds are known as working capital. In simple words, working capital refers to that part of the firms capital which is required for financing short- term or current assets such as cash, marketable securities, debtors & inventories. Funds, thus, invested in current assts keep revolving fast and are being constantly converted in to cash and this cash flows out again in exchange for other current assets. Hence, it is also known as revolving or circulating capital or short term capital. Decisions relating to working capital and short term financing are referred to as working capital management. The basic objective of working capital is to provide adequate support for the smooth functioning of the normal business operations of a company. These involve managing the relationship between a firm's short-term assets and its short-term liabilities. The goal of working capital management is to ensure that the firm is able to continue its operations and that it has IBS HYDERABAD Page 41
sufficient cash flow to satisfy both maturing short-term debt, upcoming operational expenses and meet unforeseen contingencies. Companies can follow two approaches to manage its working capital: 1) Conservative approach- This involves a lower degree of risk as it involves and increased level of current assets for a given level of sales. 2) Aggressive approach- This approach results in greater profitability but lower liquidity. The level of current assets to sales will be less as compared to that of conservative approach. Working capital management chiefly involves choosing the pattern of financing. In the normal course of business, a company usually has access to non-interest bearing short term liabilities, called spontaneous liabilities. The difference between Current assets and spontaneous liabilities needs to be financed by a combination of bank borrowings and long term sources of finance such as debentures and equity share capital. Implementing an effective working capital management system is an excellent way for many companies to improve their earnings. The two main aspects of working capital management are ratio analysis and management of individual components of working capital. Types of Working Capital: 1) On the basis of concept: a)Gross Working Capital: It is that working capital which is used for all the current assets. Total value of current assets will equal to Gross Working Capital. b)Net Working Capital: Net Working Capital is the excess of current assets over current liabilities. Net Working Capital = Current Assets Current Liabilities 1) On the basis of concept:
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a)Permanent Working Capital: It is that amount of capital which must be in cash or current assets for continuing the activities of the business. b)Temporary Working Capital: In normal working of the business we dont need temporary working capital but it may be possible that the company have to pay fixed liabilities at the time it needs working capital which is more than permanent working capital which is called temporary working capital.
will have high proportion of current assets in the form of inventory of Raw Materials and Work-in-Progress.
2) Nature of Raw Material used: Nature of the major raw material used to produce the
finished good will greatly influence the quantum of raw material inventory. In steel industry, the main source of Raw Materials, i.e., Iron Ore comes from mining. Thus, companies maintain a high level of inventory as the mining activity requires reasonably more time.
3) Process Technology Used: In case where the raw material undergoes many stages of
production, a high level of work-in-progress is held than any other item of Current Assets.
4) Nature of Finished Goods: The nature of finished goods in case of steel industry has a
longer shelf life. Also, there has been a growing demand for steel over the years. Thus, the companies operating in this industry can hold a reasonable amount of finished steel in their inventory. The level of inventory can be determined by anticipating sales in the years to come.
5) Degree of competition in the market: When the degree of competition is high in the
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so as to lure them. Practices such as this is likely to result in a high proportion of accounts receivables.
Components of working capital: There are various items which constitutes the Working Capital under the two heads namely current assets and current liabilities. 1. Current Assets:It is a balance sheet account that represents the value of all assets that are reasonably expected to be converted into cash within one year in the normal course of business.
Bills Receivable: Money which is owed to a company by a customer for products and services provided on credit. This is often treated as a current asset on a balance sheet. A specific sale is generally treated as an account receivable after the customer is sent an invoice.
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Sundry Debtors: It is an account for individuals or businesses who owe money to a company and whose information and accounts are recorded in the books of the company.
Short Term Loans & Advances: Short term loan is a loan that has to be repaid within a year, usually within a few weeks whereas advances are the prepayment received for goods or services to be rendered. Some contracts require an advance before completion (e.g., construction project).
Inventories: In terms of business it is the sum total of all the commercial assets owned by the organization whereas in terms of productions and operations it is the sum of raw materials, work in progress and finished goods held by the company.
Temporary Investment: It is a type of investment that is structured to only last for a short amount of time. With this type of investment investors can quickly access and use money invested in these temporary options. Money market fund accounts, treasury bills, and some short-term CDs are a few examples of temporary investments.
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Prepaid Expenses: A type of asset that arises on a balance sheet as a result of business making payments for goods and services to be received in the near future. While prepaid expenses are initially recorded as assets, their value is expensed over time as the benefit is received onto the income statement, because unlike conventional expenses, the business will receive something of value in the near future.
Accrued Income: Income that is earned in a fund or by company by providing a service or selling a product, but has yet to be received. Mutual funds or other pooled assets that accumulate income over a period of time but only pay it out to shareholders once a year are, by definition, accruing their income. Individual companies can also accrue income without actually receiving it, which is the basis of the accrual accounting system.
Marketable Securities: These are the very liquid securities that can be converted into cash quickly at reasonable prices. Marketable securities are very liquid as they tend to have maturities of less than one year. Furthermore, the rate at which these securities can be bought or sold has little effect on their prices.
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2. Current Liabilities:A company's debts or obligations that is due within one year. Current liabilities appear on the company's balance sheet and include short term debt, accounts payable, accrued liabilities and other debts.
Outstanding Expenses:
It is the expense in which the firm makes the provisions for the liabilities for the expenses relating to current year but actual payments incur in the next financial year.
Short term Loans and Deposits: Short term loan is a loan that has to be repaid within a year, usually within a few weeks whereas the deposit is a liability owed by the bank to the depositor (the person or entity that made the deposit), and refers to this liability rather than to the actual funds that are deposited.
Dividends Payable: It is the dollar amount of dividends which have been declared by a company's board of directors and which are obligated to be paid to shareholders.
Bank Overdraft: It is the money owed to the bank in a cheque account where payments exceed receipts.
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Provision for Taxation: It is an amount on the profit and loss statement that estimates a company's total income tax liability for the year. This is especially important when the Government or an employer does not automatically deduct estimated tax payments from pay checks or other revenue.
Bills Payable: This term is used to describe a bank's indebtedness to other banks, principally a Reserve Bank of India that is backed by collateral consisting of the bank's promissory note and a pledge of government securities. In other words, bills payable is the money a bank borrows, mainly on a short-term basis, and owes to other banks.
Sundry Creditors: Sundry Creditors refers to the companies or individuals to whom money is owed by the company.
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IN DETAIL:
SOLVENCY OF BUSINESS: Adequate working capital helps in maintaining the solvency of the business by providing uninterrupted of production. GOOD WILL: Sufficient amount of working capital enables a firm to make prompt payments and makes and maintain the goodwill. EASY LOANS: Adequate working capital leads to high solvency and credit standing can arrange loans from banks and other on easy and favorable terms. CASH DISCOUNTS: Adequate working capital also enables a concern to avail cash discounts on the purchases and hence reduces cost. ABILITY TO FACE CRISES: A concern can face the situation during the depression. HIGH MORALE: Adequate working capital brings an environment of securities, confidence, high morale which results in overall efficiency in a business.
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3. Excessive working capital implies excessive debtors and defective credit policy which causes higher incidence of bad debts. 4. It may reduce the overall efficiency of the business. 5. If a firm is having excessive working capital then the relations with banks and other financial institution may not be maintained. 6. Due to lower rate of return n investments, the values of shares may also fall. 7. The redundant working capital gives rise to speculative transactions.
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To maintain the inventories of the raw material, work-in-progress, stores and spares and finished stock.
For studying the need of working capital in a business, one has to study the business under varying circumstances such as a new concern requires a lot of funds to meet its initial requirements such as promotion and formation etc. These expenses are called preliminary expenses and are capitalized. The amount needed for working capital depends upon the size of the company and ambitions of its promoters. Greater the size of the business unit, generally larger will be the requirements of the working capital. The requirement of the working capital goes on increasing with the growth and expensing of the business till it gains maturity. At maturity the amount of working capital required is called normal working capital.
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RATIO ANALYSIS
A ratio is a simple arithmetical expression one number to another. The technique of ratio analysis can be employed for measuring short-term liquidity or working capital position of a firm. The following ratios can be calculated for these purposes: 1. Current ratio. 2. Quick ratio 3. Absolute liquid ratio 4. Inventory turnover. 5. Receivables turnover. 6. Payable turnover ratio. 7. Working capital turnover ratio. 8. Working capital leverage 9. Ratio of current liabilities to tangible net worth.
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Fund flow analysis is a technical device designated to the study the source from which additional funds were derived and the use to which these sources were put. The fund flow analysis consists of: a. b. Preparing schedule of changes of working capital Statement of sources and application of funds.
It is an effective management tool to study the changes in financial position (working capital) business enterprise between beginning and ending of the financial dates.
OPERATING CYCLE
Analysis of Operating Cycle: The Operating Cycle, also known as cash to cash conversion cycle describes the interdependence among the components of working capital. This can be explained with the help of the flow chart as shown under:
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This cycle explains that normal business activities of a company start with cash, go through the successive segments of the working capital, viz, Raw Materials storage period, Work-in-Progress conversion period, Finished goods holding period and average collection period before getting back cash along with profit. The total duration of all these items are called Gross Operating Cycle period. When the Average Payment period is deducted from the Gross Operating Cycle period, the resultant is the Net Operating Cycle Period. The Net Operating Cycle Period indicates the number of days it takes for the transformation of current assets to cash.
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CHAPTER-4
RAW MATERIAL HOLDING PERIOD: This ratio states that how much time (interms of days) raw materials have to spent in stores before sending to the production department for work-in-progress.
SIGNIFICANCE
Lesser the Raw Material Conversion Period, better for the company. This results in smoother and uninterrupted production process.
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Lesser the Raw Material Conversion Period, lesser the carrying cost, better profit & vice-versa. Greater Raw Material Conversion Period reflects inefficient & ineffective inventory management.
Raw Material Holding Period (RMHP) = Avg. Stock of raw material x 365 Total raw material consumed Where, Avg. Stock of raw material = (Opening stock + Closing stock)/2
RMHP
Opening stock of Raw Materials Closing stock of Raw Materials Average Stock of Raw Materials
ANALYSIS AND INTERPRETATION: The RMHP of Tata Steel for the year 2011 is 85 days. This indicates that 85 days worth of Raw Material Consumed is held as inventory on an average. It is noted here that RMSP is maximum for Tata Steel amongst the other current assets and the reason for it is that Tata Steel has a number of sources for Raw materials that originally comes from Mining Activities. Tata Steel has to maintain stock with itself to meet any uncertain requirements and to maintain Buffer Stock. The time period of 2008-09 was lowest and was the best during the five year period. Low value of holding period expresses the efficient operation and the momentum with which the raw materials were absorbed during this period for work in progress. This mainly happened because of the high production resulting from the commissioning of H-Blast Furnace and improvements in the other facilities and operations which sufficed the greater demand compared to the last year. The year 2009-10 had the highest value because there was a drop of 4% in the Raw materials consumed driven primarily by non-usage of imported coke. Although there was an increase in volume, prices of imported coal were at a level lower than the last year which resulted in the higher value of the raw material holding period WORK-IN-PROGRESS HOLDING PERIOD: This ratio states that how much time (interms of days) taken by the production department to convert raw materials into finished goods. SIGNIFICANCE: IBS HYDERABAD Lesser the Work-in-Progress conversion period, better the utilization of factors of production to produce finished goods. Lesser the Work-in-Progress conversion period, greater the companys ability to procure excess demands. Lesser the Work-in-Progress conversion period, better the utilization of funds in the production process for the company. Page 62
Work-in-Progress conversion period = Avg. Stock of WIP x 365 Cost of Production Where, Avg. Stock of WIP = (Opening stock + Closing stock)/2 Table 2: WORK IN PROGRESS HOLDING PERIOD:
Year WIP HP 365*Average stock of WIP Cost of Production 2011 2010 2009 2008 2007
Opening stock of WIP Closing stock of WIP Average Stock of WIP Cost of goods sold Manufacturing expenses Cost of Production WIP HP
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ANALYSIS AND INTERPRETATION: Tata Steel holds 2 days worth of Cost of Production as stock of Work-in-Progress. This reflects the efficiency in management of Work-in-Progress as a very little amount is locked in this. The work in progress was much higher in 2009-10 as compared to its previous year because there was an increase in purchase of power mainly due to additional volumes of power to cater to the requirement for additional production and also due to revision of fuel surcharge rates by DVC and increase in purchased power tariff by the Jharkhand State Electricity Regulatory Committee. Also the staff cost was higher during this year mainly due to annual increases in salary and allowances partly offset by lower charges of employee benefits towards gratuity and ESS. In the year 2010-11 the purchase of power for own use was lower as compared to the previous year and also due to marginally increased demand WIP was converted to finished goods.
Finished Goods Conversion Period = Avg. Stock of finished goods x 365 Cost of Goods Sold
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FGHP
Opening stock of FG Closing stock of FG Average Stock of FG Cost of Goods Sold FGHP
64242.1 71.98
56638.2 80.70
60687.8 73.26
38174.6 102.90
35720.6 106.20
ANALSIS AND INTERPRETATION: In the year 2011, Tata Steel held 71 days worth of Cost of Sales as average finished goods inventory. The finished goods held at Tata Steel are heavy goods and need time to produce as well as reach its destination when dispatched. There is a booming market for finished steel, thus Tata steel maintains stock to meet the increasing demand.
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We can see that the FGHP is higher in the year 2008 but is just marginally lower than the previous year. This happened because in 2007 due to the recessionary phenomena sales of steel declined but it came into track when the world economy started improving. Even though the recession hit again in 2010 but it didnt affect much of the sales because FY 11 saw a recovery, post the downturn in the FY 09 and the recession in the FY 10. Infrastructural investments in Asia (primarily in China, Korea, Taiwan, India & Japan) and increased automotive production in Asia & US resulted in improvement in the demand for steel and stainless steel bringing down the FGHP to 20.24 days. AVERAGE COLLECTION PERIOD: Table 4: AVERAGE/DEBTORS COLLECTION PERIOD:
Year DCP 365*Average Debtors Net Credit Sales 2011 2010 20009 2008 2007
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ACP indicates that in the year 2011, Tata Steel held 6 days worth of Credit sales in the form of Average Debtors. This also indicated high turnover of Accounts receivables highlighting efficiency in managing receivables. We can see that The Debtors collection period has increased which shows how quickly Tata Steel has collected the amount for its sale to other parties. This mainly happened because of two reasons. Firstly the net credit sales volume during FY 11 recorded an increase of 4% over FY 10. Higher prices across all divisions and higher volumes in Tubes, Wires and Bearings divisions also contributed to the increase in net sales. Secondly, debtors as on 31st March, 2011 declined marginally over the level as at end March 2010 due to stringent credit control measures and lower steel exports which resulted in the increase in the DCP resulting in the collection of amount in just 5.28 days. AVERAGE PAYMENT PERIOD: Table 5: AVERAGE/CREDITORS PAYMENT PERIOD:
Year CPP 2011 365*Average Creditors Net Credit Purchases 2010 2009 2008 2007
Opening Creditors Closing Creditors Average Creditors Net Credit Purchases CCP
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ANALYSIS AND REPRESENTATION: APP of Tata Steel for the year 2011 is 147 days. This indicates that Tata Steel holds 147 days worth of credit purchases in the form of Accounts Payables. This is due to the high Credibility of the company that the suppliers are willing to extend such high credit period to them. Creditors are the non interest bearing current liability. However, having a high average payment period is seen good as it leads to reduction in operating cycle. Retaining the cash and giving late to the creditors within the prescribed time is one of the business strategy followed by almost all the companies. Tata Steel is also following this strategy so that cash is retained for maximum period for working capital requirements. In the year 2007 the Creditors Payable Period is more as compared to other years because there was an expansion in the Tata Steel for 1.8 million tonnes in Jamshedpur and some money worth of rs. 255 crores were blocked on account of wages and salaries.
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ANALYSIS AND INTERPRETATION: In the year 2007-08, there was 25% increase in the amount of current liabilities and provisions due to increase in sundry creditors, which ultimately have decreased the net working capital balance. It shows that the company does not hold enough liquid assets in order to meet the current liabilities. Whereas in the year 2010-11, the net working capital is the highest due to high loans and advances given to the subsidiary companies and increased inventories. It is a good sign for the company.
A. LIQUIDITY RATIOS:
Table 7: CURRENT RATIOS: This ratio is used to judge the short term solvency of a company and is worked out by dividing the aggregate current assets by its aggregate current liabilities.
YEAR RATIOS
2011 1.18
2010 0.89
2009 1.09
2008 1.15
2007 1.63
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ANALYSIS AND INTERPRETATION: As per the conventional rule, the current ratio of 2:1 is said to be ideal for any company. In 2008, it has deceased by almost 29.44% because even though in 2008 the current liabilities remained almost same but the cash & bank balances and stock in trade decreased significantly which lowered down the ratio. The ratio has also decreased marginally by 5.21% in 2009 on account of increased current liability with subsidiary companies, 18.34% decrease in the year 2010 and 32.58% increase in 2011.The increase happened because the stock in trade and cash & bank balances increased as compared to the previous year. This shows that the company is trying to get up to the standard of 2:1 ratio and is achieving a good position.
Table 8: QUICK RATIOS: This ratio is also known as acid test ratio or liquid ratio. It is more severe test of liquidity of a company. It shows the ability of a business to meet its immediate financial commitments.
YEAR RATIOS
2011 0.76
2010 0.51
2009 0.72
2008 0.81
2007 1.27
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ANALYSIS AND INTERPRETATION: A quick ratio of 1:1 is considered favourable for a company. In 2008, quick ratio has decreased by 36.22% which is not a favourable situation for the company as compared to the previous year. In 2009 too, the ratio has decreased by 11.10%, 29.16% in 2010 and increased by 49% in the year 2011. In any of the first four years the quick assets has not crossed the standard ratio of 1:1 which is not a good sign for the company. This decrease in quick ratio occurred because the current liabilities prevailed to near around amount in all the four years but quick assets decreased to some extent on account of payments and reduction in cash & bank balances.
B. TURNOVER RATIOS:
Table 9: CURRENT ASSETS TURNOVER RATIOS: This ratio shows how effectively company uses its current asset to generate sales.
YEAR RATIOS
2011 0.61
2010 0.41
2009 0.40
2008 0.30
2007 0.36
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ANALYSIS AND INTERPRETATION: The above chart and table shows that there is decrease in current asset ratio by 16.67% in the year 2008.In the year 2009 there is a slight increase in net sales because of the increase in demand which has resulted in the increase of the ratio due to efficient use of technology to produce enough products to meet the demands and generate sales. In the year 2010 there is a marginal change in current assets turnover ratio because there was a decrease in price of steel and related products and sales were only 3% higher than the previous year. Again in 2011 there is an increase in the ratio by 20%.This happened mainly because there was an increase in prices across all divisions. This indicates that Tata Steel is trying to maintain an adequate ratio but need to pay attention to its current assets especially cash and inventories.
Table 10: INVENTORY TURNOVER RATIOS: This ratio shows that in how many days inventories are converted into net sales and generates revenue for the company.
YEAR
2011
2010
2009
2008
2007
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RATIOS
10.33
9.40
9.89
10.09
9.86
ANALYSIS AND INTERPRETATION: From the graph we can see that in 2008 there has been an increase in the ratio by 2.33%. This resulted mainly because of the increase in operations by Tata Steel. But, it decreased in 2009 by 1.98% and this happened because the prices of the products decreased thereby decreasing the ratio even though the sales were at par. But in 2010 we can see that the ratio decreased by 4.95% and this happened because of weak demand in the market. But it increased by 9,89% in 2011 because of higher purchase at Bearing division and Agrico units to support higher volumes and to support more sales of steel products. Table 11: WORKING CAPITAL RATIOS: This ratio indicates the velocity of the utilization of net working capital of the firm.
YEAR RATIOS
2011 0.36
2010 0.30
2009 0.40
2008 -0.41
2007 0.61
ANALYSIS AND INTERPRETATION: In 2008 there is a decrease in ratio leading to negative value by 167% due to negative net working capital. But in 2008-09 it has increased by almost 100% due to increase in cash, stocks and loans and advances. But again in 2009-10 the ratio has decreased by 25% even though the sales and working capital both increased as compared to previous year. In 2011 the ratio increased marginally by 20%. This happened because there was an increase in current assets. The above results indicate that Tata steel needs to pay attention towards its working capital management. Table 12: RAW MATERIALS TURNOVER RATIOS:
YEAR RATIOS
2011 24.58
2010 24.28
2009 20.82
2008 19.34
2007 20.15
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ANALYSIS AND INTERPRETATION: We can see that the Raw Material Turnover Ratios are following a particular trend in which the values are decreasing except in 2011. In all the other four years even though the value is showing the decreasing trend but it doesnt imply that the company is unable to generate enough demand or it is undergoing losses. It happened because of couple of factors i.e; the price of the raw materials decreased with recession adding the discomfort to the company. But with the increase in its operations raw materials were consumed more in 2011 which increased the value by 4.18%.
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CHAPTER-5
COMPARATIVE ANALYSIS
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Emerging Companies of the Year 2001 by The Economic Times, and as the top 20-investor friendly companies in the An ISO-9002 and ISO 14001 certified company, JSPL is committed to conducting business safely, ethically and in an environmentally responsible manner that protects the natural resources and environment. The company has been felicitated with a number of awards for its efforts towards ensuring safety and energy conservation. These primarily include the National Safety Award 2004, by the Ministry of Labor, National Energy Conservation Awards for 2001, 2002 and 2003 by the Ministry of Power, IIM Quality Award for 2000-01 and 2002-03 by the Indian Institute of Metals, the Golden Peacock Environment Management Award 2002-03 by the Institute of Directors, Rajiv Gandhi National Quality Commendation Certificate 2001 instituted by the Bureau of Indian Standards and Greentech Environment Excellence Award 2002-03 and Greentech Safety Award, 2002-03 by the Greentech foundation. Universal Beams & Columns: The Mill is also producing Hot Rolled Parallel Flange Beams & Columns for the first time in India. Typically known as H-Beams, these beams and columns are well accepted by consultants, designers and fabricators and is the material of choice internationally; because of their better statistical properties such as section modulus, radius of gyration and higher load carrying capacity under direct compression coupled with substantial cost benefits over conventionally available taper flange beams or built-up sections. Produced under Technical Services Assistance Agreement with JFE (earlier known as NKK Corporation), Japan employing Universal Rolling Technology; these sections meet exacting end-user requirements with substantial saving in steel consumption vis-a-vis conventional Beams. These H-Beams & Columns are now available in steel grades with yield strength ranging from 250 Mpa to 450 Mpa. These sections are ideally suited for construction of multi-storied buildings, bridges, flyovers, offshore structures, car parks, material handling systems, industrial systems and other industrial applications. These Universal Sections provide: Superior statistical properties Greater flexibility to designers Better value for money to end-user
Product Range encompasses H-Beams & Columns viz. NPB/ WPB Beams (conforming to IS:12778 Indian Standard), UB/ UC Sections (as per BS:4-1:1993 British Standard) and IPE Sections (as per Euronorm 19-57), Steel Grades in yield strength from 250-450 Mpa as per IS:2062 Gr B / IS:8500 Steel supporting the production of Finished Products, JSPL has the most modern steel-making capacity
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presently to the tune of 1.15million TPA through one 60 ton Electric Arc Furnace, For obtaining clean refined steel one Ladle Refining Furnace (LRF) and one Vacuum De-gassing (VD) unit are installed. One 351m3 mini-blast Furnace has been added for improving productivity and reduces cost of production of steel by using Hot Metal and sponge Iron mix. Further, a new steel melting shop is now commissioned adjacent to the Rolling Mill comprising of one 100 ton LRF, 100 ton VD unit and one Bloom-cum-Beam Blank Continuous Caster as Phase-I. Power: JSPL generates power from waste hot gases & washery rejects to meet its captive requirements. The surplus power is supplied to the Chhattisgarh State Electricity Board. The current generation of power is 265 MW. Work on another 75 MW plant is under installation. Sponge Iron at Raigarh, coal-based sponge iron is manufactured using 10 indigenously developed rotary kilns, with a capacity of 1.37 MTPA, making JSPL the largest manufacturer in the world. Mining: Iron Ore, Coal & Coal Washing Jindal Steel & Power Limited has its own captive Iron Ore Mines at Tensa, District Sundergarh, and Orissa, which produces 555,000 TPA of Iron Ore to meet the part requirement of its Sponge Iron Plant. The Company has its captive Coal Mines at Dongamahua, District Raigarh, Chhattisgarh with a present capacity of 2.0 MTPA. Since the coal is of very poor grade and quality it has to be beneficiated. Hence a coal washery with a capacity of 2.5 MTPA to wash 47-48% coal ash to 26% has been commissioned and is operating successfully. The washery meets the requirements of Sponge Iron Plant. The captive mine is the core strength of the company. To meet the increased requirement a new 3.5 million tonne coal washery has been installed. Ferro Chrome: Ferro Chrome, an essential component in the production of stainless and special steel, is manufactured at Raigarh using a Submerged Arc Furnace (SAF) with a present capacity of 36,000TPA. Continuous smelting of chrome ore, coke and quartz at temperature of 1600-17000 C ensures consistent quality of Ferro Chrome. Throughout the manufacturing process, the focus is on quality assurance; Almost the entire production of Ferro Chrome is committed to India's leading manufacturer of stainless steel. An increase in production capacity is on the anvil and global markets are being tapped to sell the increased production.
Steel Authority of India Limited (SAIL) is one of the largest steel makers in India. With a turnover of Rs. 48,681 crore, the company is among the top five highest profit earning corporates of the country. It is a public sector undertaking which trades publicly in the market is wholly owned by Government of India and acts like an operating company. Incorporated on January 24, 1973, SAIL has more than 131,910 employees. The company's current chairman is S.K. Roongta. With an annual production of 13.5 million metric tons, SAIL is the 16th largest steel producer in the world. Major plants owned by SAIL are located at Bhilai, Bokaro, Durgapur, Rourkela, Burnpur (near Asansol) and Salem. SAIL is a public sector company, owned and operated by the Government of India. According to a recent survey, SAIL is one of India's fastest growing Public Sector Units. Major Units: SAIL Integrated Steel Plants: 1. 2. 3. 4. Rourkela steel plant(RSP) in Orissa, set up with German collaboration (The first integrated steel plant in the Public Sector in India, 1959). Bhilai steel plant(BSP) in Chhattisgarh set up with Soviet collaboration (1959). Durgapur steel plant(DSP) at Durgapur, West Bengal set up with British collaboration (1965). Bokaro steel plant (BSL) in Jharkhand (1965) set up with Soviet collaboration (The Plant is hailed as the countrys first Swadeshi steel plant, built with maximum indigenous content in terms of equipment, material and know-how). IISCO Steel Plant (ISP) at Burnpur, West Bengal.
5.
Special Steel Plants: 1. Alloy Steels Plants (ASP), Durgapur, West Bengal. 2. Salem Steel Plant (SSP), Tamilnadu. 3. Visveswaraya Iron and Steel Plant(VISL), at Bhadravathi, Karnatka. Subsidiaries: 1. Maharashtra Elektro-smelt Limited (MEL) in Maharashtra. Central Units: 1. 2. 3. 4. 5. 6. 7. Centre for Engineering and Technology Research and Development Centre for iron and steel Management Training Institute SAIL safety organization Raw materials division Central Marketing Organization SAIL consultancy organization
Joint Ventures:
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NTPC SAIL Power Company Pvt. Ltd (NSPCL): A 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and National Thermal Power Corporation Ltd. (NTPC Ltd.); manages the captive power plants at Rourkela, Durgapur and Bhilai with a combined capacity of 314 megawatts (MW). It has installed additional capacity by implementation of 500 MW (2 x 250 MW Units) power plant at Bhilai. The commercial October generation of 1st Unit has commenced in Aprill2009 and the 2nd Unit in October 2009. Bokaro Power Supply Company Pvt. Limited (BPSCL): This 50:50 joint venture between SAIL and the Damodar Valley Corporation formed in January 2002 is managing the 302-MW power generating station and 660 tonnes per hour steam generation facilities at Bokaro Steel Plant. BPSCL has proposed to expand its capacity by installing 2x250 MW coal based thermal unit at Bokaro. In addition, construction activities are underway for installation of 9th Boiler (300T/Hr) & 36 MW Back Pressure Turbo Generator (BPTG) project at Bokaro. M-Junction Services Limited: A 50:50 joint venture between SAIL and Tata Steel formed in 2001. This company promotes e-commerce activities in steel and related areas. Newly added services include e-Assets sales, Events & Conferences, Coal Sales & Logistics, Publications etc.. SAIL-Bansal Service Center Ltd: SAIL has formed a joint venture with BMW industries Ltd. on 40:60 basis to promote a service centre at Bokaro with the objective of adding value to steel. Bhilai JP Cement Ltd: SAIL has incorporated a joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.2 MT slag based cement plant at Bhilai. The company shall commence cement production at Bhilai by March'2010, whereas clinker production at Satna shall start within 2009. Bokaro JP Cement Ltd: SAIL has incorporated another joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.1 MT cement plant at Bokaro utilizing slag from BSL. The project implementation is under progress with commencement of cement production likely by July2011. SAIL & MOIL Ferro Alloys (Pvt.) Limited: SAIL has incorporated a joint venture company with M/s Manganese Ore (India) Ltd on 50:50 basis to produce ferro-manganese and silico-manganese required for production of steel..
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S&T Mining Company Pvt. Ltd: SAIL has incorporated a joint venture company with TATA Steel for joint acquisition & development of coal blocks/mines. New indigenous opportunities for coking coal development are being explored by the Joint Venture company for securing coking coal supplies. International Coal Ventures Private Limited: Towards achieving the target of making steel PSUs self-reliant in the area of coking coal, a joint venture company has been incorporated comprising of five central PSU companies i.e. SAIL, Rashtriya Ispat Nigam Limited (RINL), Coal India Limited (CIL), NTPC Limited and National Mineral Development Corporation (NMDC). The company is scouting for coal properties in Australia, Mozambique and other target countries. Achievements:
SAIL was featured in the 2008 list of Forbes Global 2000 companies at position 647. National Institute of Personnel Management conferred the National Award on SAIL for Best HR Practices 2008. SAIL was adjudged as the top Indian company under the Iron and Steel Sector for the Dun & Bradstreet Rolta Corporate Awards 2008.
Operating Cycle of JSW and SAIL: Operating Cycle of JSW OPERATING CYCLE OF JSW 2011 2010 2009 2008 147548.5 Raw Material Consumed 0 104,608.20 87,357.00 58,835.30 Average Stock of Raw Materials 15872.30 10401.5 8099.95 7150 Raw Material Holding Period 39.26 36.29 33.84 44.36 PARTICULARS Cost of Production(cost of goods sold +manufacturing expenses) Average Stock of WIP WIP Turnover Ratio=Average Stock of WIP*365/Cost of prod. Cost of Goods Sold average stock of FG FG Conversion Period=Average Stock of Finished Goods*365/Cost of Goods Sold credit sales Average Debtors=(Opening Debtors + 211666.10 1889.70 3.75 183925.10 10800.60 112046.20 1337.10 5.48 89080.40 7342.35 95233.80 1202.65 5.55 79157.50 5614.85 66164.60 631.00 4.44 51915.90 3283.8
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Closing Debtors)/2 Debtors Turnover Ratio=Credit Sales/Average Debtors Days Debtors Turnover=365/Debtors Turnover Ratio GROSS OPERATING CYCLE Purchases Average Creditors=(Opening Creditors + Closing Creditors)/2 Creditors Turnover Ratio=Purchases/Average Creditors Days Creditors Turnover=365/Creditors Turnover Ratio NET OPERATING CYCLE 33.04 11.05 75.50 142541 18100 2.32 843.74 -711.92 37.86 9.64 81.50 104606.8 16168.9 2.02 734.35 -591.37 43.32 8.43 73.71 84501 14265.75 2.36 860.33 -707.24 42.63 8.56 80.44 56938.5 8590.65 2.06 751.59 -590.05 35.34 10.33 85.41 40299.5 6043.4 1.58 591.63 -428.05
Opearting Cycle of SAIL: OPERATING CYCLE OF SAIL Particulars 2011 2010 2009 Raw Material Consumed 202520 160370 200769.2 Average Stock Of Raw Materials 28610.25 26335.8 20115 Raw Material Holding Period 51.56 59.94 36.57 Cost Of Production(Cost Of Goods Sold +Manufacturing Expenses) Average Stock Of WIP WIP Turnover Ratio=Average Stock Of WIP*365/Cost Of Production Cost Of Goods Sold Average Stock Of FG FG Conversion Period=Average Stock Of Finished Goods*365/Cost Of Goods Sold Credit Sales Average Debtors=(Opening Debtors+Closing Debtors)/2 294386.2 0 0 220806.2 53962.35 245249.7 0 0 173429.7 52391.15 282471.4 0 0 202067.7 48814.05
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Debtors Turnover Ratio=Credit Sales/Average Debtors Days Debtors Turnover=365/Debtors Turnover Ratio Gross Operating Cycle Purchases Average Creditors=(Opening Creditors+Closing Creditors)/2 Creditors Turnover Ratio=Purchases/Average Creditors Days Creditors Turnover=365/Creditors Turnover Ratio Net Operating Cycle
COMAPRATIVE ANALYSIS OF RATIOS: INVENTORY TURNOVER RATIOS: INVENTORY TURNOVER RATIO TATA Year/Company STEEL JSW 2011 10.33 6.89 2010 9.40 7.85 2009 9.89 8.85 2008 10.09 9.73 2007 9.86 8.88 INVENTORY TURNOVER RATIOS:
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ANALYSIS AND INTERPRETATION: The inventory turnover ratio is high for Tata steel and JSW having very less fluctuations every year. It shows that the velocity of turning inventory into sales is good, which shows companys inventory management is highly effective. On the other hand, the ratio is low for SAIL. The company should work on its inventory turnover, which can be done by shortening the operating cycle in number of days taken from the purchase of raw materials to its conversion into sales and getting money back from the customers, to be utilized again to purchase the raw materials for further production.
DEBTORS TURNOVER RATIOS: DEBTORS TURNOVER RATIO Year/Company TATA STEEL JSW 2011 66.21 5.93 2010 45.43 5.47 2009 40.20 5.20 2008 32.59 4.56 2007 29.10 4.03 DEBTORS TURNOVER RATIOS:
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ANALYSIS AND INTERPRETATION: Receivables management indicates managements efficiency in getting the money back into the organization in the shortest period of time. The debtors turnover ratio reflects the number of times the money received from debtors is rotated in the business cycle in a year. The Debtors Turnover Ratio of Tata steel is the best indicating the managements efficiency in getting the money back from the debtors and again rotating it in the business to generate sales. Whereas, JSW and SAIL should adopt more stringent policies in order to have effective debtors management.
DEBTORS TURNOVER PERIOD: COMPARATIVE DEBTORS TURNOVER PERIOD Year/Company TATA STEEL JSW SAIL 2011 5.28 61.55 32.97 2010 7.70 66.74 29.48 2009 8.72 70.26 25.65 2008 10.24 80.05 25.00 2007 12.01 90.58 18.00
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ANALYSIS AND INTERPRETATION: The debtors collection period is low for Tata Steel. It shows that company is less prone to the risk of converting debtors receivable into bad debts. Whereas JSW and SAIL should adopt effective debtors management policies in order to avoid difficulties in future.
CREDITORS TURNOVER RATIOS: COMPARATIVE CREDITORS TURNOVER RATIO Year/Company TATA STEEL JSW SAIL 2011 3.71 2.31 3.64 2010 3.90 2.01 3.34 2009 3.51 2.36 5.96 2008 2.92 2.06 4.9 2007 2.26 2.31 3.64
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ANALYSIS AND INTERPRETATION: The creditors turnover ratio is low for JSW indicates that the credit worthiness of the company is not good. It should pay to the creditors on time or take some limited amount of time. So that it can get credit in the future and not be harmful for the company. On the other hand Tata Steel shows a good position by having less creditors turnover ratio.
CREDITORS TURNOVER PERIOD: COMPARATIVE CREDITORS TURNOVER PERIOD TATA Year/company STEEL JSW SAIL 2011 98.29 843.74 100.27 2010 93.55 734.35 109.28 2009 104.03 860.33 61.24
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124.76 161.52
751.59 591.63
74.49 54.48
ANALYSIS AND INTERPRETATION: Creditors turnover period is very high for JSW. It can damage the relationships with the creditors by affecting their credit worthiness. Tata Steel has optimum creditors turnover period indicating efficient credit management compared to other two.
CHAPTER-6
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INVENTORY MANAGEMENT
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Inventories generally constitute the most significant part of current assets of most of the manufacturing companies, especially in India. They are approximately 60% of the total current assets in a company. Inventories are the 2nd largest constituents of the total assets, standing next to the plant and machinery of an organization. Considerably large amount of funds are committed towards inventories, hence arises great need to manage them effectively and efficiently. A firm which neglects the management of inventories, may jeopardize in the long run, and may fail ultimately. The use of simple inventory planning and control techniques will reduce excessive inventories which in-turn will have a favourable impact on the companys profitability.
NATURE OF INVENTORY:
The various forms in which inventories exist in a manufacturing company are: Raw Materials Work in progress Finished goods
There is one more kind of inventory that many manufacturing concerns maintain, i.e., Supplies or Stores and Spares.
Transactionary motive: It emphasises the need to maintain inventories to facilitate smooth production and operations.
Precautionary motive: It necessitates holding of inventories to guard against the risk of unpredictable changes and contingencies in demand and supply or other factors relating to inventories.
Speculative motive: It influences the decision to increase or reduce inventory levels to take advantage of price fluctuations.
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Hence, an effective inventory management should: Ensure a continuous supply of raw material to facilitate uninterrupted production. Maintain sufficient stocks of raw materials in periods of short supply and anticipate price changes. Maintain sufficient finished goods inventory for smooth sales operation leading to efficient customer service. Minimize the carrying cost and time Control investment in inventory and keep it at an optimum level.
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The first question can be answered by determining the ECONOMIC ORDER QUANTITY (EOQ). The second question, when to order is answered by determining the RE-ORDER POINT.
Ordering costs: it includes the entire costs of acquiring raw materials. They include the costs of the following: 1) Requisitioning 2) Purchase ordering 3) Transportation 4) Receiving
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Carrying costs: costs involved in maintaining a certain level of inventory are known as carrying costs. They include the following: 1) Storage 2) Insurance 3) Taxes 4) Deterioration and Obsolescence 5) Warehousing 6) Stores and handling 7) Administrative
Where, EOQ=Economic order quantity A= Quantity required B= Ordering cost C= Carrying cost
RE-ORDER POINT
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The reorder point is that level of inventory at which an order should be placed to replenish the inventory. To determine the Reorder point under certainty, we should know:
Lead time: is the time normally taken in replenishing the inventory after placing the order. Average usage: is the average use of the inventory in production cycle. Economic order quantity: is the quantity of material to be ordered.
With these in place, the Reorder point is calculated by: Re-order point= lead time average usage
The following steps are involved in implementing the ABC analysis: Classify the items of inventories, determining the expected use in terms of price per unit for each item. Determining the total value of each item by multiplying the expected units by its unit price. Rank the items in accordance with the total value, giving first rank to the one with highest value and so on. Compute the ratio of number of units of each item to total units of all items and the ratio of value of each item to total value of all items. Combine items on the basis of their relative value to form three categories-A, B and C.
VED ANALYSIS
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VED, defined as VITAL, ESSENTIAL and DESIRABLE, is a classification based on the criticality of the component, as defined by the users. Non-availability of the vital parts may result in the closure of the entire factory. It is based on considerations such as stock out cost, safety, security, design, functionality, reliability, maintainability, guarantee, performance, operational aspects, etc. the user has the responsibility to classify the materials under these heads, and has to avoid the temptation to categorize all items as vital. This system is applicable in stores and spares.
It has also to be aware of various costs related to the above mentioned items in order to make appropriate inventory decisions. In a manufacturing concern, a major portion of the funds employed is blocked in inventories which form a large chunk of the current assets. That is why it is necessary for a manufacturing concern to carefully invest in inventories keeping in mind that it has enough liquid assets to meet emergencies. Almost every aspect of inventories is SAP automated. Tata Steel has adopted the concept of Theory of Constraints (TOC) in order to efficiently and effectively handle inventories. TOC is a process where improvement is carried in continuously based on the logic that there is at least one constraining factor in an organization that limits its rate
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of goal attainment. This constraining factor is identified by TOC and the entire concern is remodeled around it. This remodeling is done on the basis of five focusing steps: 1) Identification of the constraint 2) Deciding the methods of exploiting the constraint 3) Aligning the remaining processes to the above decision. 4) Expanding the constraints if possible. 5) Repeating the above cycle if it results in the removal of the constraint. Through the five focusing steps, the organization not only encounters the constraint but also takes advantage of it.
For efficient management and timely availability of all the inventories, Tata Steel has formed various departments to be responsible for different categories of inventories. Raw materials are maintained by Raw Material Handling Department (RMHD), finished goods are maintained by Customer Service Department (CSD) and stores and spares are maintained by the Raw Material Handling Department (SMD). There is no particular department for work-in-progress. The various user departments are accountable for it. The primary departments are explained in detail below:
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This department was formed on 1st May, 2001. It deals with the raw materials required for manufacturing steel. Tata Steels Indian operation has raw material security of 80%. Approximately 35000 tonnes of raw materials are regularly procured for its production activities around Rs. 80 crores. The various raw materials consumed by Tata Steel are as follows: Iron ore Coal Coke Limestone and Dolomite Zinc and Zinc alloys Spelter, Sulphur and other materials
Tata Steel acquires most of its raw materials from its own mines and collieries. About ninety eight percent of the raw materials are brought from the mines and collieries by rail. Raw materials are brought into the Tata Steel, Jamshedpur plant by around 10 goods train or 580 wagon called rakes. Inside plant raw materials are carried to different departments by trucks. Tata Steel has 3 exchange yards, namely Tata Nagar Exchange Yard, New Reception Yard and Adityapur Railway Yard. RMHD takes care of all the requirements of consuming departments within the plant. A central stocks yard is maintained by the department where buffer stocks of major raw materials are available. RMHD is also responsible for disposing waste materials and recycling and utilizing solid by products. The department has the following sections through which it satisfies the needs of different production departments: Raw Material Stock Yard MRH (ore) Page 100
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These sections are associated with raw material planning, quantity and quality control, receiving and unloading of materials, maintaining balance between demand and supply, demurrage wagon deficiency accounting and many more functions. Tata Steel procures its entire iron ore inventory from its own mines such as Joda maines ans Noamundi mines. The basic types of iron ore are: Lump ore Fine ore LD ore
Lump ore is used in blast furnace, Fine ore in sinter plant and LD ore in steel melting plant. The approximate average consumption of these ores is 10000 tonnes, 20000 tonnes and 1000 tonnes respectively. The company keeps a stock of only about 8 hours to transport the iron ores from the mines to the plant at Jamshedpur. So, safety stock of lump ore is about 50000 tonnes and fine ore is about 100000 tonnes. LD ore should have an ideal stock of about 5000 tonnes but during monsoon more stock is kept because LD ore needs to be kept dry. Tata Steel procures coal from its own collieries as well as from outside India. There are 2 main types of coal.
COAL
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Domestic coking coal is produced from collieries at Jamadoba, Bhelatand and West Bokaro. The approximate average per day requirement of coking coal from Jamadoba and Bhelatand is 1500 tonnes respectively; from West Bokaro is 6000 tonnes and that of imported coal is 7000 tonnes. The level of inventory for domestic coking coal is of 5 days and that of imported coking coal is 21 days. PCI coal has an average per day requirement of about 2500 tonnes and Tata Steel maintains about 50-60 days inventory of this item. Around 7000 tonnes of imported non coking coal is maintained on a daily basis and its desired level of inventory is also about 21 days. Imported coals are received at ports in Haldia and Paradeep. In case of emergency Vizag port is also used. Tata Steel has also entered into a venture with Hooghly Met Coke and Power Company Ltd.(HMCPCL). It is a 100% subsidiary of Tata Steel and is situated in West Bengal. This project satisfies the need of metallurgical coke at the blast furnace in the Jamshedpur plant. Merchant coke oven units have been set up for this purpose. In case excess heat is produced in the coke oven process, Tata Power Company Limited uses the heat to produce electricity with a power capacity of about 120 MW. Limestone is mainly of two types: CP Grade limestone SP Grade limestone
CP Grade limestone is calsinised plant and used in LD shops whereas SP Grade limestone is used in sinter plant and blast furnace. Domestic CP Grade limestone is procured from Jaiselmer. The average per day requirement for both domestic and imported CP Grade limestone is around 3500 tonnes and the desired level is 15 days inventory. IBS HYDERABAD Page 102
Similarly, domestic SP Grade limestone is procured from Gotan in Rajasthan and many places a\in central India. The average per day requirement of both domestic and imported SP Grade limestone is around 2000 tonnes and the desired level is 10days inventory. Pyroxenite is acquired from Sukhinda and is used in blast furnace and sinter plant. The daily requirement is around 1000 tonnes and safety stock is about 15000 tonnes. Quartzite is used in blast furnace. The daily requirement is around 200-300 tonnes and safety stock is about 5000 tonnes. All the above requirements are managed by the Raw Material Handling Department. The RMHD prepares a monthly schedule of raw material requirements at the beginning of the year. Domestic collieries and mines provide raw materials according to this schedule only. Imported raw materials are received annually. So orders are placed after carrying out a through survey of the future demand because adjustments cannot be made easily for unexpected changes.
2. CUSTOMER SERVICE DEPARTMENT(CSD):
The customer service department is responsible for delivering finished goods to the customers and executes them. It receives orders from customers and executes them. It converts orders into final delivery. Earlier the department was involved in controlling production but now it looks after customer satisfaction which is very important in building brand and increasing sales. The CSD efficiently uses logistics to speed up transportation and warehousing of finished goods. External processing agents facilitate the above process. Satisfying the customers is the main job. If customers are satisfied only then can an organization grow. So the CSD has to coordinate with the sales, marketing, advertising, production and procurement divisions to satisfy customers. Tata Steel has 19 stock yards throughout the country to facilitate the delivery of the products and services to the customers. CSD attempts to specialize on fronts like delivery accuracy, total deliver cost, optimum inventory and lead time so that the company can ve a front runner in the current competitive environment.
3. SUPPLY MANAGEMENT DEPARTMENT (SMD):
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The Supply Management Department is also known as the stores department and handles stores and spare parts consumables like aluminum, calcium, iron, cold wire, zinc, manganese, etc. for stores and spare parts the head MRO and head Process Consumables are responsible. Stores and Spares are used in all departments of Tata Steel. The entire SMD is SAP oriented. Tata Steel deals in flat products like cold rolling mils, hot strip mills, LD2 and slab caster and long products like merchant mills, wire and rod mills and LD1. SAP categorizes flat and long products as profit centres, iron ore as cost centre and Stores and Spares as Shared services. SAP has a plan for all departments. Plant 073 is assigned to supply management. Stores available in Plant 073 can be used by all departments. Material Reservation slips are placed by departments requiring the material. If materials are available in stores then delivery is made within 24 hours. All materials are issued through SAP except safety items which are issued manually. FIFO system of valuation is used. In Tata Steel, as soon as the goods enter the stores, a Goods Receipt Department (GRD) is prepared which carries the quantity of material received. Once the quantity and quality matches specifications, Q-11 is issued. If there are any modifications, they are made in QA-12. The final document is issued on SAP Screen QA-13 as it displays items which cannot be altered. Stores department also performs the important function of invoice verification. After the suppliers supply the materials, they shall produce challans with particulars like order placed, quantity supplied, price quoted for payment, etc. All calculations regarding Economic Order Quantity, minimum and maximum levels are done through SAP. ( Due to insufficient data, calculation of the above has not been possible). Tata Steel has around 50000 main items apart from 10000 other items. The storekeeper should be very careful regarding the maintenance of stocks. There should be neither over stocking nor under stocking of materials because under stock might lead to unavailability of materials when required and overstocking will lead to unnecessary blockage of capital which could otherwise be invested in better option. The Jamshedpur Plant stores items on the basis of ABC classification. However, SAP is responsible for spares procurement. SAP categorizes spares or materials as follows: VM-which is similar to type A and B and helps to plan reorder point automatically.
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W-which is similar to C and is used to make forecasts. ZR-consists of items which are not classified either under either type A, B or C. These items may belong to category D and is useful for planning requirements of slow moving items.
Materials are categorized into the above classes according to their requirements. Spares, which are purchased immediately after a new plant is commissioned, are called Vital Spares or Insurance Spares and they fall under Initial Spares. The department requiring spares and the project team are responsible for identifying initial spares. If the spares are unique and required by a single user, then the consuming department is responsible for the process of planning the requirement. However, if the spares are required by multiple users, then the entire procurement team becomes responsible for the process of planning, buying and storing spares. Materials are issued from the stores under the FIFO method of stock valuation. This task of planning spares is very difficult because there is no fixed consumption pattern of spares.
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Category D consists of around 80% of stores and spares. Requirement planning for these items are done manually and not through SAP. VED ANALYSIS-The Company has nearly two lakh items of spare parts. One lakh items out of these have been classified under VED. These items are procured through E-Procurement Systems. FSN ANALYSIS-MRO stores and spares are controlled through this technique. Under this method, most of the items are classified under A, B and C categories are termed as fast moving goods. Requirement planning of such goods are termed as fast moving goods. Requirement planning of such goods are done through SAP. The remaining items are termed as slow moving goods and these items are planned manually. Stores and spares used to keep old machineries and assets up-to-date are termed as non-moving or obsolete. VENDOR MANAGED INVENTORY SYSTEM- In this case vendors look after the level of inventory in an organization. They supply inventory depending upon the requirements of the organization. These vendors may operate either from their own workshops or from the place provided by the company within their campus. As in the case of Tata Steel, different types of lubricants are issued to Tata Steel whenever required by Indian Oil Corporation which has its depot inside works. Only after the supplies have been consumed does Tata Steel make the payment. In the current year, 27% of the inventory will be controlled through VMI system as compared to 17% last year. Even British Oxygen Corporation has its depot inside Tata Steel. JUST-IN-TIME SYSTEM-Items such as refractories are managed under this system because the suppliers of such items are situated near production units. The external processing agents deliver items as and when required. FIRST IN FIRST OUE METHOD (FIFO)- Tata Steel uses this method to issue inventories from stores to different departments on the basis of their requirements. This method is followed so as to save inventories from obsolescence.
Work in progress is carried at lower cost and net realizable value. Coal, iron ore, and other raw materials produced and purchased by the company are carried at lower cost and net realizable value.
Purchased raw materials in transit carried at cost. Stores and spares are carried at below cost. Cost of inventory is generally ascertained on weighted average basis. WIP, Finished goods, and Semi finished goods are valued on full absorption cost basis.
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Different kinds of inventory reports are prepared monthly to report about the stocks maintained by the company. Inventory maintained by the company at a certain point in time is compared with that of the previous month and the previous year and the difference is recorded. This comparison is made both in terms of value and volume. The reports are made category wise which summarizes the particulars of the overall inventory stocks of finished and semi- finished goods, raw material and stores and spares with the company. Another repot that is prepared gives details of the total inventory of the company division-wise. The division where the inventory is maintained is divided into two- steel division and other division. This report gives information regarding the inventory stocks kept by each division and accordingly analyze the changes over the previous month and year. This reported is supported by another detailed report which shows break-up of inventory between raw material, finished goods and stores and spares. The finished goods are again reported in a comprehensive manner as flats, long, scrap and other products which are again divided as saleable and re rollable products. Inventory-wise reporting is also done. Separate reports are prepared for finished and semi-finished inventory, raw material and stores and spares. For finished and semi finished inventory the reporting is done by all the above mentioned departments depending on the different types maintained by them at various locations. Raw material inventory reporting is done in an elaborate way. Reporting is broken down as raw material for steel works, mines and colleries and other divisions. In case of steel works the raw material maintained is divided into five categories and reported. They are ; Coal ,coke and ores Metals Ferro alloys Imports In-transit
Again for mines and colleries there are four heads which are further sub-divided. IBS HYDERABAD Page 108
They are; West bokaro colleries Jharia collieries Mines Tailings at west bokaro colliery and jharia colliery.
Lastly the report of stock at other divisions is prepared. Since raw material is the most important component of inventory in a production unit like tata steel,its reporting is done in an extensive manner. Similar to finished and semi finished goods ,the inventory of stores and spares is also reported division wise. All the above reports are compiled into a master report which gives complete picture of the entire stock with the company. Apart from this ,three special reports are also prepared : saleable steel summary report ,raw material summary report and stores and spares summary report. Theses are highly structured reports which give the minutest of details of inventory. The stock of finished steel is maintained at mostly at four locations namely steel works, stockyard and consignment agents ,external processing agents and in-transit agents. Likewise for consignment agents ,stockyards, external processing agents and in-transit stock inventory is reported depending on the types of inventory held by them. The raw material summary report gives in depth details about the different varieties of coal coke ferro alloys and other materials based on the places where these are procured . This report is more elaborate than the earlier raw materials report prepared by the company. The materials are classified and re-classified for reporting purpose.Stores and spares are primarily classified as spare, operating consumables and packaging material. Almost all departments make use of stores and spares. Inventory reporting at Tata Steel is a detailed and complex process. This is primarily because of the numerous types of inventories maintained by the company. Every department has a different requirement for materials based on its functions and produce different end products. Accordingly IBS HYDERABAD Page 109
their reporting schedule also varies. It becomes a cumbersome job for the officials of the finance department to classify data, compile it, and prepare varied reports. Classification of inventory is the most difficult task for the department. The importance of reporting system cannot be undermined as it provides vital information regarding stock levels of different inventories and facilitate the decision making process.
CHAPTER-7
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CONCLUSION
As explained earlier, inventory management is integral ro the growth of any firm. Inventory is directly related to the working capital of an organization. Proper management of inventory leads to proper flow of working capital. Tata Steel has been able to manage its onventory quite satisfactorily which is shown by the high inventory turnover of the company. Tata Steel has closely monitered ENTERPRISE RESOURCE PLANNING systems as a result of which it has an up-todate SAP technology in place. The entire Supply chain is SAP oriented which makes it one of the most efficient systems in the entire steel industry. Tata Steel has a raw material security of 80%, which means 80% of raw materials come from Tata Steels own mines and collieries. Also the proximity of these mines are an added advantage to the company. Overall, Tata Steel has proper inventory management techniques in place. The MANAGEMENT INFORMATION SYSTEM at Tata Steel is also up-to-date. We have identified and examined the main elements of working capital. We have seen that the management of working capital requires an evaluation of both the cost and the benefits associated with each element. Some of these costs and benefits may be hard to quantify in practice. Some assessment must be in order to try and optimize the use of funds within a business. We have examined various techniques for management of working capital. These techniques vary in their sophistication; some rely heavily on management judgement, while other adopts a more objective, quantitative approach. Tata Steel maintains sound position interns of working capital. Its efficiency in receivable and deferral management is reflected in the constantly decreasing operating cycle. The company has primarily been operating on cash drawn from the market and reaping full benefits of its brand name. Inventory which constitutes an important component of working capital in a steel manufacturing company has also been managed well. This is evident from the high inventory IBS HYDERABAD Page 111
turnover in comparison to the industry average. However, the conversion period of raw material needs to be worked upon. The company has a well built supply chain and all its processes of inventory maintenance are SAP linked. It has a competent control system in place for managing stores, spares and finished goods. Nevertheless there is scope for improvements in raw material management.
FINDINGS:
1. The idle current ratio for any firm is 2:1. The current ratio of Tata steel except in 2007 is far less than the standard ratio. 2. The quick ratio of any firm should be 1:1 but that of Tata Steel is quiet less. 3. Tata Steel has implemented effective strategies to reduce cost of production and is enjoying high operating profit than other firms by lowering production cost. 4. Tata Steel is managing its inventories by following different inventory control tools for different items. 5. Tata Steels Debtors Collection Period is less which signifies the availability of liquid assets most of the time. 6. Tata Steel is also following a good strategy for blocking its funds for a longer period of time when it comes for payment. 7. As part of the financing of the imports for the 2.9 mtpa expansion in Jamshedpur, the Company also tied up long-term ECA backed buyers credit of 72.85 million to be drawn over the next 18 months and repaid over the next ten years.
8. Tata Steel has been engaged in many expansion projects through which it has
invested around rs. 13288 crores including expansion in Jamshedpur plant increasing the steel capacity to 9.2 mtpa.
RECOMMENDATIONS:
1. The Company should look forward to maintain the standard current ratio and quick ratio. 2. Although the creditors payable period is high for Tata Steel but far less as compared to JSW. The Company can devise a strategy to increase the payable period so that liquid assets will be available to meet the unforeseen events.
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3. At this moment the Company should hedge their most of the funds because of the volatility of exchange rate. 4. The essence of effective working capital is proper cash flow forecasting. This should take into account the impact of unforeseen events, market cycles and competitors movement. So the effect of unforeseen demand should be factored in. 5. Advance payment should be avoided or else should be made against securities.
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