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Material Management


Production & Materials Managemnt

Production & Materials Managemnt

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  • 1. Material management
    The 5 M’s of production are men, machines, money, materials and methods.
    Materials management is the branch of logistics that deals with the tangible components of a supply chain. This covers the acquisition of spare parts and replacements, quality control of purchasing and ordering such parts, and the standards involved in ordering, shipping, and warehousing.
  • 2. Importance
    The money spent on materials is highest (55-80% of total costs)
    Maximum scope of cost reduction
    Add value to the product
    Quality of finished goods depends upon the quality of materials
  • 4. Functions involved in Materials Management
    Transformation Processes
    In-process Storage
  • 5. Functions in Material Management
  • 6. Functions in Material Management
    1. Production Control :
    The function of production control aims at directing and regulating the movement of goods through the entire manufacturing cycle. Departments involved in this function are :-
    • Purchasing department
    • 7. Receiving department
    • 8. Raw materials inventory department.
    • 9. Production department
  • Production Control:
    Purchasing department
    • To acquire the required materials in the right quantity, of the right quality, from the right source, at the right time and at least possible cost.
    • 10. Centralized purchasing
    • 11. Decentralized purchasing
    Receiving department
    Processes incoming shipments of materials. The tasks unpacking incoming materials checking their quantity and inspecting their quality and generating receiving reports.
  • 12. Production Control
    Raw materials inventory department
    Involves repackaging and labeling raw materials, storing raw materials safely and protecting them from damage, updating records of quantities of various raw materials, arranging for the replenishment of stocks.
    Production department
    • Objective is to keep the flow of materials continuous during the process of production.
    • 13. Monitoring the flow of work-in-process materials, identifying bottlenecks and minimizing them, computing the storage capacity.
  • Inventory Level
    Supply Rate
    Inventory Level
    Demand Rate
    Water Tank Analogy
    Managing physical movement of materials through and out of the firm.
    The primary objective of the material handling deprtment material handling is to move materials to required location in a timely and cost effective way.
    Material handling equipment are of two types:
    Fixed path: conveyors, monorail devices
    Variable path: Trucks, forklifts, mobile cranes
  • 16. Systems :
    Just-in-Time Systems: Aims at reduction in the size of purchased quantities so that the materials reach the production point completely.
    Supply chain management: includes purchase of raw material its flow and ends with finished products delivered to ultimate customers. It includes purchasing, warehousing, inspection, production, material handling and distribution.
    Warehouse management system: It is a key part of the supply chain and primarily aims to control the movement and storage of materials within a warehouse. The systems also direct and optimize stock put away based on real-time information.
  • 17. ECIL – case study
    Electronics Corporation of India Ltd.(ECIL) is a Public Enterprise .
    The CrisisPost- liberalization period of the 90s was characterized by intense competition from both the MNCs and private sector.
    The impact of the globalization process , ECIL suffered a loss of Rs.10 crore in 1997-98 and a substantial loss of Rs.60 crore in 1998-99.
    The net worth of the company was badly eroded.
  • 18. The Initiatives in Materials Management
    • Material costs of 55-60 % of the total cost, it was difficult to introduce initiatives in the area of materials management with respect to the nature of global electronics business characterized by high rate of obsolescence, falling prices, high quality inputs and global sourcing
    • 19. There was no assured market, customer-driven requirements and threat of denials.
    • 20. It is against this background that the entire supply chain was addressed
  • Supplier Communication It was ensured that the requirements of the customers of ECIL are clearly communicated to the suppliers, thus making the latter jointly responsible for ensuring customer satisfaction. This is done through constant touch with the suppliers
    Inventory Control The scheduling process was streamlined to ensure efficient inventory management .
    Implementation of IT All the processes involved in Materials Management are fully computerized for speedy disposal of material requisitions, resulting in substantial reductions in lead times across various operations.
  • 21. The Results
    Between 1998-99 and 2002-03:
    Turnover shot up from Rs. 250 crore to Rs. 1000 crore
    Profitability reversed from a loss of Rs. 60 crore to a profit of 130 crore
    Net worth increased from Rs. 7 crore to Rs. 309 crore
    Loans Outstanding became nil
    Inventory levels and Sundry Debtors demonstrated efficient Working Capital Management.
    Procurement lead-times reduced substantially
    Customer Satisfaction Index improved phenomenally from 66% to 95%
  • 22. Hypothetical Case-Study
    a number of small organizations to adopt /adapt material and logistic systems practised by large organizations.
    Such small organizations are giving more importance to constructive rationalization, quality management systems and material loss studies.
  • 23. The company being a small one has a number of constraints
    To overcome these constraints, the company tried evaluating its processes and the following were the findings
    Defined role and accountability for each individual
    Supply plans elaboration
    Site layout planning
    Increasing speed in data processing
    Reduction in interference among subcontractors and agents
    Optimum usage of stored capacities even with limited work force
  • 24. To improve this scenario the company opted to diffuse “Just-in- Time” into its production system
    Principle of JIT:
    • To improve its situation, the company chalked out a plan with the help civil engineers
    • 25. the exact quality, quantity of raw materials
    • 26. number and type of labor required
  • The company also used Supply Chain Management.
    The main focus in this system was to limit the number of suppliers, minimize change of suppliers and thoroughly evaluate suppliers
    The company ensured that civil engineers inspect raw materials before unloading
    The company improved its warehousing conditions
    There were civil engineers checking the process
    Some checks were at regular intervals whereas some at random.
    They also ensured rewards for successful production teams.
  • 27. During this exercise the company implemented:
    • Site preparation phase
    • 28. Site layout planning
    • 29. Material Handling Systems
    • 30. Information system
    Conclusion: The above measures helped the company achieve its targets with respect to time, cost with the same quality. This helped to company to offer a competitive price to its customers.
  • 31. Latest Developments
    ROBOTS: they are reprogrammable and multifunctional manipulators designed to perform a variety of tasks. They are of two types:
    Processing: the robot works as a tool by performing a job on a product like cutting, screwing etc. but this article should move to the robot.
    Pick-and-place: these robots are more relevant to material handling. They perform tasks like assembling and testing. Recently developed robots respond to stimuli like touch, light and can be effectively used to mix chemicals and also handle radio active materials.
  • 32. ROBOTS can be based on their operations:
    Physically operated robots: have a primary objective of protecting workers from using harmful materials like radioactive substance.
    Fixed sequence robots: these perform a sequence of operations according to a predetermined set of procedures.
    Variable-sequence robots: performance is flexible thus can be easily changes while their functioning is similar to that of fixed sequence robots.
    Numerical control robots: (NC robots) perform a set of operations based on numerical data that is fed into them through devices. These robots are used to perform manufacturing operations where high precision is required.
    Playback robots: store a sequence of operations in memory.
  • 33. GEOCODING:
    High-quality, real-time address-validation tools can help improve operational efficiencies of business.
    To Optimize Delivery:
    Geocoding enables you to provide a clearer, smarter picture of just how to deliver for your customers. With it, addresses are linked to specific latitudes and longitudes — not just streets and zip codes.
    Geo coding can also add any number of geographic characteristics to enrich your data with added relevance and usability.
    Weather and disaster-related information;
    proximity to important distribution centers or stores
    traffic and construction updates;
    tax jurisdictions;
    and area shipping restrictions
  • 34. Determining ways to optimize all aspects of delivery from point of origin, to loading of goods, to routing deliveries, to tracking of items in transit.
    Situations such as bad weather /natural disasters, terrorism or political unrest delays caused by parades, protests, rallies or construction projects that temporarily render an address inaccessible.
  • 35. Point-to-point optimization: automatically maps out the very best routes, right down to putting your trucks on the right side of each street for the most efficient delivery.
    • This new emerging global trend involves the material handling processes and procedures to be carried out in the most eco-friendly manner .
    • 36. Promotes the concept of “REDUCE- REUSE- RECYCLE”.
    • 37. This involves reducing the potential environmental impact that arise due to the various internal processes of material procurement and dispatching processes like transportation, material waste disposal etc .
    • 38. This is now considered to be a part of a firm’s Corporate Social Responsibility.