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Material
           Management
           Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D
                     Department of Pharmaceutics
                  KLE University College of Pharmacy
                  BELGAUM-590010, Karnataka, India.
                    E-mail: nanjwadebk@gmail.com
                      Cell No.: 00919742431000
There are thousand reasons for failure, but only one way to success,
                        ‘HARD WORK’
Contents
Definition

Objective and importance

Principles of material management

Functions of material management

Materials – Quality and Quantity
19 July 2012   KLE College of Pharmacy, Nipani.   2
Contd..
                   Contents
 Value analysis

 Purchasing

 Vendor development

 Buying techniques

 Purchasing cycles and procedure

 Advantages of material management
 19 July 2012      KLE College of Pharmacy, Nipani.   3
Definition

      It is defined as an organizational concept,
    which has the authority and responsibility of
    all activities, concerned with the flow of
    materials in the organization.




19 July 2012     KLE College of Pharmacy, Nipani.   4
Objectives and importance
• Efficient use of the working capital.
• Lowering inventory investment and increasing
  the inventory turnover.
• Responding to the market changes related to
  any product.
• Ensuring the cooperation of all departments.
• Providing best services to the king of the
  market i.e customer.
19 July 2012    KLE College of Pharmacy, Nipani.   5
Principles of material handling

• Least handling is the best handling.

• Lengths and number of move to be
  minimized.

• Unit loads

• Minimize the distance.
19 July 2012    KLE College of Pharmacy, Nipani.   6
Principles of material handling
• The design of the container.e.g. shippers
  are used for storing finished bulk. & for
  raw materials as per the property of
  materials they are stored- plastic
  containers ( light weight containers)

• Re-handling and back tracking of the
  materials should be avoided.

• The materials handling service should not
  interfere with the production flow.
19 July 2012         KLE College of Pharmacy, Nipani.   7
Classes of materials

• Raw materials:- These are materials that
  are used in the product which is in an
  unprocessed condition.

• Purchased Parts:- These are the items
  used in the assembly of the product.



19 July 2012        KLE College of Pharmacy, Nipani.   8
Classes of materials
• In-progress materials:- They are called
  ‘work in progress’ inventories. These
  goods require further processing.

• Finished materials:- These are fully
  manufactured goods, inspected and ready
  for delivery to the customers.

• Supplies:- These are consumable goods
  used in the process of manufacturing.
19 July 2012        KLE College of Pharmacy, Nipani.   9
Functions of material management




19 July 2012    KLE College of Pharmacy, Nipani.   10
Materials-Quality & Quantity
•     Four factors affecting the purchase of raw
      materials are
    1) Quality :- The suitably of an item to
      accomplish the intended work.
          The raw materials should satisfy the
      following requirements.
i. Efficiency of the material.
ii. Cost and the shelf –life.
iii. For equipments, power consumption and
      power requirement.
19 July 2012      KLE College of Pharmacy, Nipani.   11
Quantity

•      From the inventory point of view, quantity
       standards are decided on the following
       parameters;
i.     Maximum inventory
ii.    Minimum inventory
iii.   Standard order
iv.    Reorder point
 3)    Price
 4)    Delivery Date
19 July 2012       KLE College of Pharmacy, Nipani.   12
Value Analysis
•    Definition:- It is a systematic study of every
     element for it’s cost in a part, material or service to
     make certain that it performs it’s function at the
     lowest possible cost.
• Benefits of value analysis:-
i. Decrease in existing cost of the product or service.
ii. Unnecessary expenditure is identified and
     eliminated.
iii. Product value improves for new materials and
     processes.
iv. More profits.
19 July 2012        KLE College of Pharmacy, Nipani.      13
Value ratio

Mathematical representation of the value can be
   done as                      Function
              Value =           Total cost

Reasons for unnecessary costs:-
i. Lack of information
ii. Lack of ideas
iii. Changed circumstances
iv. Wrong beliefs, habits and attitudes
19 July 2012    KLE College of Pharmacy, Nipani.   14
Value Analysis Technique


  In this technique (n) number of questions are
  applied, like:-
o what must I do?
o What else does the item do?
o What does it cost?
o What else will the job do?
o What will be alternative costs?

 19 July 2012       KLE College of Pharmacy, Nipani.   15
Purchasing
Centralized :- the purchasing           Decentralized:-      different
  procedure of materials for              department purchase their
  different department is done            requirement      seperately.
  together      from       one            This is basically seen in
  purchasing       department.            large organizations.
  This is seen in small
  organizations.                        Advantages
                                         Flexible purchasing system
Advantages                               Procurement is faster
 Efficient system
 Bargaining       capabilities
  increased
 Good raw material obtained
  at lower price
 19 July 2012         KLE College of Pharmacy, Nipani.            16
Vendor development
          The supplier or the person who sells the
       required materials or services for the
       production is known as a vendor.

        The purchase of raw materials/service from a
       specific vendor is known as the vendor
       development.

       There are four stages of vendor development:-
19 July 2012       KLE College of Pharmacy, Nipani.   17
Four stages of vendor development

      Stage          Name                          Development
                Survey stage               Identifying the potential
          1st                              sources of suppliers.
                                           Seeking information.
                                           Provisional vendors list.
                Enquiry stage              Analysis of information in
          2nd                              standard enquiry format.
                                           Accreditation, FDA
                                           approval, ISO certification.
                                           Personal visits.
                Negotiations and           Quality control
          3rd   selection stage            specifications, clarification,
                                           credit, quantity discounts.
                Experience and             Performance appraisal,
          4th   evaluation stage           Quality, delivery time.


19 July 2012         KLE College of Pharmacy, Nipani.                       18
1) Survey stage

The following sources are considered for information
• Trade directories :- e.g.
  Yellowpages.eindiabusiness.com
• Trade journals:- e.g. Pharmatimes
• Telephone directories
• Supplier’s catalogue
• Salesmen
  Other ways are like interchanging of information
  with other companies, tracing of public tenders and
  advertisements in the press.
19 July 2012     KLE College of Pharmacy, Nipani.   19
2) Enquiry stage
       After getting the information of the suppliers,
      detailed analysis of the supplier is being
      carried out. A comparison is being made
      between the different suppliers on basis of the
      following points:-

a.    Technological competition,
b.    service competition,
c.    price competition,
d.    delivery time.
19 July 2012       KLE College of Pharmacy, Nipani.   20
2) Enquiry stage

The following aspects can be verified by the first
  hand visit:-
 Internal facilities of the vendor
 Financial adequacy, stability and reputation of
  the vendor
 Location of vendor’s factory
 After sales service
 Industrial relations

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3) Negotiation and selection stage

• The vendors who clear the enquiry stage are
  selected and negotiations are being carried out
  with them.

• The various aspects such as credit, quantity
  discount, quality specifications are being
  discussed.


19 July 2012      KLE College of Pharmacy, Nipani.   22
4) Experience and evaluation stage

• The buyer evaluates and appraises the
  performance of the vendor.
• The objective is to improve the performance
  of the vendors.
  Few ways of evaluating a vendor are:-
o Categorial method
o Weighted point method
o Cost ratio method

19 July 2012    KLE College of Pharmacy, Nipani.   23
Categorial method
The buyer sets up some category on which the evaluation of the vendor is done. Specimen
of supplier’s evaluation form is given below.
                                               Grading

       Factors            Always         Usually          Seldom          Never
                        9   8    7     6   5     4      3    2   1          0

 Supplies are as per
 quantity selected
 Deliveries are on
 time

 Rigorous follow up
 is not necessary
 Willing to
 accommodate when
 production schedules
 are suddenly
 changed
 19 July 2012                KLE College of Pharmacy, Nipani.                       24
Weighted point method
Here the rating points are divided between quality,
delivery and price.

For eg         quality – 50 points
               delivery- 30 points
               price – 20 points so total is 100 points.

The rating can be obtained by following equation.


19 July 2012           KLE College of Pharmacy, Nipani.    25
Weighted point method
Quantity rating = (no. of lots accepted/ no. lots
                    received) ×rating points

Delivery rating = (no of lots delivered on time/ no
                  of lots delivered) × rating points

Price rating =(least offer received/ supplier’s
 offer)
               × rating points
 19 July 2012        KLE College of Pharmacy, Nipani.   26
Buying techniques
  Purchasing of material , machinery and services
 is done by purchasing department.

 For buying the material company has to pay up a
 price, the value that a seller sets on his goods in
 the market is called as the price of that good.

  Price is one of the greatest variables in the
 purchasing of material.
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How is the purchasing done????

• Quotations :- It is a kind of an inquiry done to
  know whether the vendor can supply the desired
  material and at what price.
• They are not the purchase order. They just contain
  all the details including freight, taxes and many
  other costs.
• The highly used quotation techniques are
• Spot quotations
• Floating a limited enquire
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How is the purchasing done????

• Spot quotations:- this is basically used for the small
  items not related to the technical purpose.

   The prospective buyer goes to the market and gets the
  quotations from the different suppliers.

• Floating a limited enquire:- this method is used when the
  value of the purchase is small. In this technique the
  reliable vendors are called upon and asked to provide the
  quotations.
 19 July 2012       KLE College of Pharmacy, Nipani.    29
How is the purchasing done????
• Tenders:-
            It is a written letter or a published document
  that is aimed at finding the price for procuring certain
  materials.

   Tenders are invited from recognized firms. A few
   types of tenders are:
   # single tender
   # Open tender
   # Closed tender or limited tender
19 July 2012       KLE College of Pharmacy, Nipani.      30
How is the purchasing done????
• Single tender:- It is invited from one reliable
  supplier. This kind of tender is floated only when
  the itms are required urgently.

• Open tender:- Also known as ‘ press tender’. This
  is used when the value of item to be purchased is
  very high. It is used to locate more suppliers.
    In this tender procured, a small amount of the
  deposit money is taken from the supplier so that
  they do not withdraw from the submitted rates.


19 July 2012      KLE College of Pharmacy, Nipani.   31
How is the purchasing done????
• Closed tender or limited tender (Negotiations):-
  It is done to arrive at the mutual understanding
  between the supplier/vendor and the buyer.




19 July 2012      KLE College of Pharmacy, Nipani.   32
How is the purchasing done????
What’s the need for negotiation?
@ prices are related to large volumes or to a large value.
@ terms and conditions are required for large volumes.
@ contract is desired for a longer period.
@ variations in quantity to be purchase are possible.
@ when supplies or services can be obtained from only
 one source.
@ when no acceptable quotations are received from the
 other vendors.

19 July 2012      KLE College of Pharmacy, Nipani.      33
How is the purchasing done????
    Process of negotiations:- It is a kind of win-win situation.
    Both the parties try to benefit to the maxima through the
    negotiation.
    It is not a kind of bargaining but a mutual understanding
    between the two parties.




19 July 2012          KLE College of Pharmacy, Nipani.        34
How is the purchasing done????
•  Discounts:- They are cash concessions offered by the vendor to
   the buyer, in order to enhance the volume of the business
   opportunities.
              Reasons for offering discounts?????
              ! When there is a bulk purchase.
              ! When the bills are cleared immediately.
              ! And also to maintain the good rapo with
                the buyer
Types of discounts:-
1) Volume contracts.
2) Deals
3) Discounts
4) Consignment terms
19 July 2012         KLE College of Pharmacy, Nipani.        35
How is the purchasing done????
 # Volume contracts:- This kind of discount is offered
 proportionate to the volume of material ordered.

# Cash discount:- Cash discount is given on the basis of
 the time of the payment done by the purchaser. The
 normal credit period is 90 days.

# Cumulative discount:- It is a method of offering the
 discount on the basis of actual purchases and appropriate
 to the quantity range in a year.

19 July 2012       KLE College of Pharmacy, Nipani.    36
Purchasing cycle and procedure
•   The purchasing department of the company is
    responsible for the purchase of all the raw materials as
    well as the requirements.
The following steps are followed in the purchasing cycle.
1) Recognition of need and receipt of requisition: The
    requisition includes the following information:-
   - Name
   - Quality and quantity specifications
   - Date by which material is required
   - Place at which material is to be delivered
    19 July 2012      KLE College of Pharmacy, Nipani.   37
Purchasing cycle and procedure
2) Selection of potential sources of supply
3) Making request for quotation
4) Receipt and analysis of quotations
   - material specifications and quality
   - price of the material
   - taxes
   - terms of payemeny
   - place of delivery
   - delivery period
   - gurantee period
   - validity of tender
19 July 2012       KLE College of Pharmacy, Nipani.   38
Purchasing cycle and procedure
5) Selection of right source of supply
6) Issuing the purchase order
7) Follow-up of the order
8) Receipt of materials,reports and analysis
9) Checking and approving of vendor’s invoice for
  payment
10) Closing of completed order
11) Maintenance of record and file
    Purchasing cycle flow chart has been given in the
  following slide.
19 July 2012      KLE College of Pharmacy, Nipani.   39
Spell out of specifications &
         Need recognition                   requirements

                                                   Official requisitions

                                 Check specifications,
Specifications                                                              Purchase
                                 prices/supplies
file                                                                        records

               Inquiry tender                  Select suppliers             Supplier’s
                                                                            record

               Quotations & analysis prices and terms, negotiations, finalisation


                                         Purchase order for supply


                                                  Suppliers’ acceptance
                  Follow-up
19 July 2012                    KLE College of Pharmacy, Nipani.                       40
• Contd ….

                             Delivery of materials


  Checking of invoice        Materials & reports,
  with purchase order        analysis


                                 Payment made




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Example of Materials and People Flow




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Location of Stores :
 Store should be located adjacent to the manufacturing area.

It depends up on nature and value of items to be stored and
  frequency with which items are received and issued

  Objectives :
   Minimum wastage of space
   Maximum ease of operation
   Minimum handling cost
   Minimum other operational cost
19 July 2012         KLE College of Pharmacy, Nipani.           43
Facilities of Store

Inspection center
Quarantine room
Washing room
Centralized weighing department
Adequate space


19 July 2012        KLE College of Pharmacy, Nipani.   44
Functions of stores

   General function :
 Maintenance of Stock (materials and tools)

 Maintenance of hygiene, sanitation, and
  pest control

 Maintenance of material handling
  equipment
19 July 2012       KLE College of Pharmacy, Nipani.   45
Functions of stores
     Specific functions :
 Receiving & recording of raw materials
 Quarantine storage – Sampling & approval by QC
 Positioning & Storage
 Issuing & recording of materials
 Receiving & Dispatching of finished goods
 Distribution

     Optional functions :
 Dispensing, Maintenance of weights & measures
19 July 2012       KLE College of Pharmacy, Nipani.   46
Material handling system
Right Definition :
                    Material handling uses the right
  method to provide the right amount of the right
  material at the right place, at the right time, in
  the right sequence, in the right position, in the
  right condition, and at the right cost.



 19 July 2012    KLE College of Pharmacy, Nipani.   47
Material handling system

Involves handling, storing, and controlling material
• The raw materials, in-process materials and
  finished goods are moved from one place to
  another in the plant.
• Adds value through time and place utility
• Impacts space requirement, profits, quality, safety,
  and productivity
• On an average, 20% of production cost is spent on
  material handling system
19 July 2012     KLE College of Pharmacy, Nipani.   48
Twenty Principles of Material Handling


1. Planning principle. Plan all material handling
    and storage activities to obtain maximum overall
    operating efficiency.


2. System principle. Integrate as many handling
    activities as is practical into a coordinated system
    of operations, covering vendor, receiving, storage,
    production, inspection, packaging, warehousing,
    transportation. etc.

 19 July 2012        KLE College of Pharmacy, Nipani.   49
Twenty Principles of Material Handling


3. Material flow principle. Provide an operation
  sequence and equipment layout optimizing
  material flow.

4. Simplification principle. Simplify handling by
  reducing, eliminating, or combining unnecessary
  movement and/or equipment.

5. Gravity principle. Utilize gravity to move material
   wherever practical.
19 July 2012        KLE College of Pharmacy, Nipani.   50
Twenty Principles of Material Handling



6. Space utilization principle. Make optimum
  utilization of space .

7. Unit size principle. Increase the quantity, size,
  or weight of unit loads or flow rate.

8. Mechanization principle. Mechanize handling
  operations.


19 July 2012        KLE College of Pharmacy, Nipani.   51
Twenty Principles of Material Handling



9. Automation principle. Provide automation to
  include production, handling, and storage
  functions.

10. Equipment selection principle. In selecting
  handling equipment, consider all aspects of the
  material being handled.



19 July 2012        KLE College of Pharmacy, Nipani.   52
Twenty Principles of Material Handling



11. Standardization principle. Standardize handling
  methods as well as types and sizes of handling
  equipment.

12. Adaptability principle. Use methods and
  equipment that can best perform a variety of
  tasks and applications where special purpose
  equipment is not justified.


19 July 2012        KLE College of Pharmacy, Nipani.   53
Twenty Principles of Material Handling


13. Dead weight principle. Reduce ratio of dead
  weight of mobile handling equipment to load
  carried.

14. Utilization principle. Plan for optimum utilization
  of handling equipment and manpower.

15. Maintenance principle. Plan for preventive
  maintenance and scheduled repairs of all
  handling equipment.
19 July 2012        KLE College of Pharmacy, Nipani.   54
Twenty Principles of Material Handling


16. Obsolescence principle. Replace obsolete
  handling methods and equipment when more
  efficient methods or equipment will improve
  operations.

17. Control principle. Use material handling
  activities to improve control of production
  inventory and order handling.



19 July 2012        KLE College of Pharmacy, Nipani.   55
Twenty Principles of Material Handling



18. Capacity principle. Use handling equipment to
  help achieve desired production capacity.

 19. Performance principle. Determine
  effectiveness of handling performance in terms
  of expense per unit handled.

20. Safety principle. Provide suitable methods and
  equipment for safe handling.


19 July 2012        KLE College of Pharmacy, Nipani.   56
Handling of materials must be performed

    Safely
    Efficiently
    At low cost
    In a timely manner
    Accurately (the right materials in the right
     quantities to the right locations)
    And without damage to the materials


19 July 2012     KLE College of Pharmacy, Nipani.   57
Risks associated with improper handling
• Increase in cost of raw material and finished
  products
• Delay in production schedule and long
  production cycle
• Waste of machine time and personnel time
• Increase in in-process inventories
• Damage or loss of material and employee safety
  liabilities
• Employee frustration and reduced morale
• Customers dissatisfaction

19 July 2012     KLE College of Pharmacy, Nipani.   58
Selecting Material Handling System

  Systematic Approach

    1. Define the problem




19 July 2012       KLE College of Pharmacy, Nipani.   59
Selecting Material Handling System

2.       Analyze the problem
   Observe activities
   Obtain layouts, flow patterns, schedules, etc.
   Obtain information on existing material handling
  equipment
   Analyze situation by Twenty Principles of Material
  Handling, and/or forms
   Can activities be combined, simplified,
  eliminated???

19 July 2012      KLE College of Pharmacy, Nipani.   60
Selecting Material Handling System

3.        Identify possible solutions
    Organize meeting with:
    material handlers
    machine operators
    supervisors
    support engineers
4.        Evaluate alternatives
          Meet again to rate alternatives
19 July 2012         KLE College of Pharmacy, Nipani.   61
Material Handling Equipment

 Five categories:
 1. Industrial trucks
 2. Automated guided vehicles
 3. Monorails and other rail guided vehicles
 4. Conveyors
 5. Cranes and hoists

19 July 2012   KLE College of Pharmacy, Nipani.   62
Industrial Trucks

Two basic categories:
1. Non-powered
     – Human workers push or pull loads


1. Powered
     – Self-propelled, guided or driven by human
     – Common example: forklift truck


19 July 2012      KLE College of Pharmacy, Nipani.   63
Nonpowered Industrial Trucks
            (Hand Trucks)




     (a) Two-wheel hand truck,                (b) four-wheel dolly,
               (c) hand-operated low-lift pallet truck

19 July 2012            KLE College of Pharmacy, Nipani.              64
Powered Trucks




                            Capacities from 450 kg up to 4500 kg
           Power sources include on-board batteries and internal combustion motors

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Powered Trucks
•Designed to pull
one or more trailing
carts in factories and
warehouses, as well
as      for     airport
baggage handling

•Powered by on-
board batteries or IC
engines


 19 July 2012       KLE College of Pharmacy, Nipani.   66
Automated Guided Vehicles
  An Automated Guided Vehicle
  System (AGVS) is a material
  handling system that uses
  independently operated, self-
  propelled      vehicles guided
  along defined pathways in the
  facility floor

• Types of AGV:
   – Driverless trains
   – Pallet trucks
   – Unit load AGVs

 19 July 2012            KLE College of Pharmacy, Nipani.   67
Driverless Automated Guided Train
 • First type of AGVS to
   be introduced around
   1954
 • Common application
   is moving heavy
   loads over long
   distances in
   warehouses and
   factories without
   intermediate stops
   along the route

19 July 2012    KLE College of Pharmacy, Nipani.   68
AGV Pallet Truck

• Used to move palletized
  loads               along
  predetermined routes
• Vehicle is backed into
  loaded pallet by worker;
  pallet is then elevated
  from floor
• Worker drives pallet truck
  to AGV guide path and
  programs destination

   19 July 2012      KLE College of Pharmacy, Nipani.   69
Unit Load Carrier
• Used to move unit
loads from station to
station
• Often equipped for
automatic
loading/unloading of
pallets and pans using
roller conveyors,
moving belts, or
mechanized lift
platforms


 19 July 2012      KLE College of Pharmacy, Nipani.   70
AGVs Applications
1. Driverless train operations - movement of large
   quantities of material over long distances
2. Storage and distribution - movement of pallet loads
   between shipping/receiving docks and storage racks
3. Assembly line operations - movement of car bodies
   and major subassemblies (motors) through the
   assembly stations
4. Flexible manufacturing systems - movement of
   work parts between machine tools
5. Miscellaneous


 19 July 2012       KLE College of Pharmacy, Nipani.   71
Rail-Guided Vehicles
• Self-propelled vehicles that ride on a fixed-rail
  system
• Vehicles operate independently and are
  driven by electric motors that pick up power
  from an electrified rail

• Fixed rail system
  – Overhead monorail - suspended overhead
    from the ceiling
  – On-floor - parallel fixed rails, tracks
    generally protrude up from the floor
19 July 2012        KLE College of Pharmacy, Nipani.   72
Overhead Monorail




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Conveyor Systems
•        Large family of material transport equipment
         designed to move materials over fixed paths,
         usually in large quantities or volumes


      1. Non‑powered :
       Materials moved by human workers or by gravity
       2. Powered :
       Power mechanism for transporting materials is
         contained in the fixed path, using chains, belts,
         rollers or other mechanical devices
    19 July 2012      KLE College of Pharmacy, Nipani.   74
Conveyor Types

•    Roller
•    Skate‑wheel
•    Belt
•    In‑floor towline
•    Overhead trolley conveyor


19 July 2012     KLE College of Pharmacy, Nipani.   75
Roller                        Skate‑wheel                             Belt




                                                          Overhead trolley conveyor
         In‑floor towline
19 July 2012                KLE College of Pharmacy, Nipani.                          76
Cranes and Hoists
Handling devices for lifting, lowering and transporting
  materials, often as heavy loads
• Cranes
   – Used for horizontal movement of materials
• Hoists
   – Used for vertical lifting of materials
• Cranes usually include hoists so that the crane-
  and-hoist combination provides
   – Horizontal transport
   – Vertical lifting and lowering
 19 July 2012         KLE College of Pharmacy, Nipani.   77
Hoist




                                     Load



19 July 2012   KLE College of Pharmacy, Nipani.   78
Bridge Crane      Gantry Crane                     Jib Crane




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Salvaging and Disposal of
             Scrap and Surplus

     The words ‘Scrap’ and ‘Surplus’
     symbolize waste and to that extent these
     account for the loss of profits.

     Scrap is commonly used for waste of all
     kinds.


19 July 2012     KLE College of Pharmacy, Nipani.   80
These occur for the following reasons:

 Mistakes in procurement
 Wrong planning decisions
 Wasteful processes in production
 Inevitable waste during the adjustment of
  the equipment
 Overall absence of efficiency


19 July 2012   KLE College of Pharmacy, Nipani.   81
 Disposal of scrap, surplus, recyclable, obsolete
  materials is one of the most important area of
  materials management, but often overlooked or
  considered minor.

 Popular due to increased public awareness of
  environment, government legislation, better
  recognition of opportunities it offers in return.

  e.g. paper files and forms are recyclable item
   that can be sold to recycle company.
19 July 2012     KLE College of Pharmacy, Nipani.     82
The following measure are adopted and
       monitored for handling scrap:

 1. Controlling of surplus and scrap
 2. salvaging or converting the waste for
    advantageous use.
 3. Disposal of the surplus and scrap to the
    best advantage.


19 July 2012     KLE College of Pharmacy, Nipani.   83
The production department primarily controls the first
     function by proper design, while purchase
     department handles the second and third functions.

    Waste materials in pharmaceutical industry:

• Empty drums, packing materials, card boards,
  aluminium caps, bottles etc. these are non-
  recoverable rejects.
• Spoiled materials during production. In a few
  instances, these may be recoverable.
• Worn-out parts of equipments (examples are
  punches and dies), old equipment (due to expiry of
  life) and obsolete equipment (due to technology
  change).
19 July 2012        KLE College of Pharmacy, Nipani.    84
Salvage :
       It is defined as the processing of materials
    (items) for advantageous use or disposal of
    company property, which is no longer
    economically useful in its present position.

  Salvage operation :
 Waste materials are properly collected and
  stored at one place continuously, so that these
  can form a separate batch in production.
 Recoverable materials are stored in a scientific
  way as other items stored.
19 July 2012      KLE College of Pharmacy, Nipani.    85
 Materials are stored in terms of quality or size or
  specifications.
 Waste is invested for suitability to recover or avoid them.

 Salvaging operation are possible under the following
  conditions:
    Evidences from laboratory tests and assays that the drug
  products meet all applicable standards of identity, strength,
  quality and purity.

         Evidence from inspection of premises that the drug
    products and their associated packing were not subjected to
    improper storage condition, as a result of the disaster or
    accident.

19 July 2012          KLE College of Pharmacy, Nipani.        86
Disposal

    Disposal of scrap, waste and surplus
  materials can be effected by several way :

 Surplus material should be returned to the
  original supplier. Alternatively a customer who
  needs them should be explored.
 As a social obligation, some material are
  defected or broken before selling them as scrap.
 19 July 2012    KLE College of Pharmacy, Nipani.   87
Disposal

 Materials may be sold by inviting quotations
  from potential buyers or through various
  contracts such as fixed price contract, varying
  price contract, specific bids and negotiations.

• It is worth considering that scrap like any other
  material represents money and to that extent it
  has a value.


19 July 2012    KLE College of Pharmacy, Nipani.   88
Unit lode, Pelletization and
                 Containerization
 Unit load is a set of items (raw material, semi
  finished parts, finished product) to be move
  together, like:
 A set of cartons on a pallet
 A set of products in a container

   In a unit load, parts are
    In something (In a carton)
    On something (On a pallet)
    Grouped by something (wrapped, strapped)
19 July 2012      KLE College of Pharmacy, Nipani.   89
Reasons for using unit loads in material
                      handling

   Multiple items
   handled
   simultaneously
   Required number
   of trips is reduced
   Loading/unloading
   times are reduced
   Product damage is
   decreased           (a) Wooden pallet, (b) pallet box, (c) tote box
19 July 2012          KLE College of Pharmacy, Nipani.          90
 Pallets :
  Style and Size based on:
 Shipping and receiving restrictions
 Size and weight of items on the pallet
 Space restrictions
 Equipment used to move the pallet
 Cost, supply, and maintenance
 Aisle widths, door sizes, stacking heights

19 July 2012    KLE College of Pharmacy, Nipani.   91
 Types of Pallets :




 Materials used :                     • Plastic
• Softwood                              • Steel
• Hardwood                            • Aluminium
• Paper
19 July 2012   KLE College of Pharmacy, Nipani.     92
Containerization :

  Different types of containers are used according to
  the type of material.
e.g
  Boxes, cartons, cases, sacks, bales, pallets,
  drums, barrels, crates, cable drums, machinery,
  and processed timber
• Tank containers for bulk liquids and dangerous
  goods.
19 July 2012      KLE College of Pharmacy, Nipani.   93
TRAINING AND DEVLOPMENT

• Training and development may be defined as an
  attempt to improve current or future performance
  of employees through learning, usually by
  changing the employees attitude or increasing
  his/her skills and knowledge.




19 July 2012    KLE College of Pharmacy, Nipani.   94
TRAINING AND DEVLOPMENT
•         Training and development program - Steps :
      I. Explain the trainee what is the job, how is the
            job done and why is it done (relevance).
      II. Show how the job should be done
            (demonstration).
      III. Allow the trainee to do the job (practice).
      IV. Follow up by explaining what was done
            correctly and what was done incorrectly.
            Correction always should be made as
            privately as possible (feedback).
    19 July 2012     KLE College of Pharmacy, Nipani.   95
TRAINING AND DEVLOPMENT

•        Training and development program –
         Methods :

          I.   On-the job training

          II. Off-the job training



19 July 2012          KLE College of Pharmacy, Nipani.   96
TRAINING AND DEVLOPMENT
I.       On-the job training :
           Majority of industrial training are on-the job
         training, because it is related to the
         productivity.

          On-the job training refers to methods that are
         applied at the workplace, while the employee
         is actually working.



19 July 2012         KLE College of Pharmacy, Nipani.   97
TRAINING AND DEVLOPMENT
II.      Off-the job training :
              This method is commonly used for the
         training of employees.

         Off-the job training refers to methods that are
         applied away from workplace.




19 July 2012         KLE College of Pharmacy, Nipani.   98
JOB ANALYSIS



• Job analysis is defined as a process of collecting
  and studying information relating to the
  operations and responsibilities of a specific job.




19 July 2012     KLE College of Pharmacy, Nipani.   99
JOB ANALYSIS
• Process of job analysis :
                        Defining uses of job analysis


                          Information collecting

                          Information processing




               Job description                 Job specification

19 July 2012             KLE College of Pharmacy, Nipani.          100
JOB ANALYSIS
• Uses of job analysis :

     • Personnel planning

     • Training and development

     • Work scheduling

     • Performance appraisal

     • Job evaluation

19 July 2012        KLE College of Pharmacy, Nipani.   101
JOB ANALYSIS

• Job Description :
     is defined as a combination of statement
  containing the work to be performed and the
  essential working conditions of a particular job.

• Job specification :
     may be defined as a statement of human
  qualities and other desirable characteristics
  required for discharging the assigned job.
19 July 2012    KLE College of Pharmacy, Nipani.   102
JOB ANALYSIS
                       Job Analysis

Job description                            Job specifications
Job title                                            Education
Job place                                            Experience

 Job summary                                         Training
 Machines, tools and equipment                       Judgment
 Materials and forms used                            Initiative
Working condition                                   Responsibilities
Hazards
19 July 2012     KLE College of Pharmacy, Nipani.
                                                    Physical effort 103
JOB DESIGN
• Job design involves conscious efforts to
  organize tasks, duties and responsibilities into a
  unit to achieve objectives.

• Job design involves three steps.
     – Specifications of individual tasks.
     – Specification of the methods of performing each
       tasks.
     – Conversion of tasks into specific jobs to be assigned
       to individuals.

19 July 2012         KLE College of Pharmacy, Nipani.    104
JOB DESIGN

• Mechanisms of job design :
     Understanding the nature of job is important,
    because it determines the skill requirement in
    performing a job.

               Skill variation, responsibility and growth
    Low                                                     High
                   Enlargement and enrichment



19 July 2012            KLE College of Pharmacy, Nipani.       105
Job enlargement

      It involves performing of a variety of jobs or
       operations at the same time. It is mainly
       intended to enlarge the job horizontally.

      It avoids monotony, as a result of high degree
       of specialization, but the basic nature of job
       remains same. Therefore, it has limited role in
       motivating employees. There is a need for up-
       gradation of authority and responsibility.


19 July 2012       KLE College of Pharmacy, Nipani.   106
Job enrichment


      It acts as an additional motivating factors to
       other models described earlier in job design.
       This factor attracted more attention, both in
       academic circles as well as in practice.
       Therefore, it requires a detailed study.




19 July 2012       KLE College of Pharmacy, Nipani.   107
Job enrichment


 Job enrichment is concerned with designing of
  job in terms of the following :
   • Work content provides greater variety.
   • Levels of knowledge and skills are higher.
   • More autonomy and responsibility in terms of
     planning, directing and controlling is given to
     workers for their own performance.
   • Work experience becomes meaningful.


19 July 2012     KLE College of Pharmacy, Nipani.   108
BLUE AND WHITE-COLLAR JOBS

• A position that involves mainly physical labor.
  With the decline in manufacturing and an
  increase in harmonization agreements, the term
  blue collar is now rarely used.

• Blue collar refers to the blue overalls traditionally
  worn in factories in contrast to the white shirt
  and tie supposedly worn by an office worker,
  known as a white-collar worker.

19 July 2012      KLE College of Pharmacy, Nipani.   109
LABOR WELFARE
• Labor Welfare means working out things for the
  well-being of the labors. Knowing there wants
  and enabling them to fullfill there wants.


• Labor welfare is the voluntary efforts of employer
  to establish within the existing industrial system,
  working and sometimes living and cultural
  conditions of the employee beyond what is
  required by law.

19 July 2012     KLE College of Pharmacy, Nipani.   110
Advantages of material management

• It eliminates unproductive handling of the
  materials like back-tracking, rehandling
  etc.

• It reduces idle machine capacity and thus
  ensures better turnover on investment.

• It reduces considerably the idle time of the
  workers.
19 July 2012     KLE College of Pharmacy, Nipani.   111
Advantages of material management
• The quality of the materials is also maintained
  through minimum human touches, elimination of
  breakages, etc.

• Every inch of the factory space is properly
  utilized.

• The issue of materials is also facilitated.

• It helps in maintaining effective production
  planning and control.
19 July 2012      KLE College of Pharmacy, Nipani.   112
Advantages of material management
• Reduced operating                   costs         and   timely
  production.

• Greater job satisfaction on the part of both
  the workers and the employer.




19 July 2012     KLE College of Pharmacy, Nipani.             113
References

• CVS Subrahmanyam; Pharmaceutical
  Product and Management, Published by-
  Vallabh Prakashan, Page no :- 260 – 282

• S.C. Saksena; Business Administration
  Management, Published by- Sahitya
  Bhawan, Page no :- 262 – 263, chapter
  20.
19 July 2012   KLE College of Pharmacy, Nipani.   114
19 July 2012   KLE College of Pharmacy, Nipani.   115

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Material management

  • 1. Material Management Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D Department of Pharmaceutics KLE University College of Pharmacy BELGAUM-590010, Karnataka, India. E-mail: nanjwadebk@gmail.com Cell No.: 00919742431000 There are thousand reasons for failure, but only one way to success, ‘HARD WORK’
  • 2. Contents Definition Objective and importance Principles of material management Functions of material management Materials – Quality and Quantity 19 July 2012 KLE College of Pharmacy, Nipani. 2
  • 3. Contd.. Contents  Value analysis  Purchasing  Vendor development  Buying techniques  Purchasing cycles and procedure  Advantages of material management 19 July 2012 KLE College of Pharmacy, Nipani. 3
  • 4. Definition It is defined as an organizational concept, which has the authority and responsibility of all activities, concerned with the flow of materials in the organization. 19 July 2012 KLE College of Pharmacy, Nipani. 4
  • 5. Objectives and importance • Efficient use of the working capital. • Lowering inventory investment and increasing the inventory turnover. • Responding to the market changes related to any product. • Ensuring the cooperation of all departments. • Providing best services to the king of the market i.e customer. 19 July 2012 KLE College of Pharmacy, Nipani. 5
  • 6. Principles of material handling • Least handling is the best handling. • Lengths and number of move to be minimized. • Unit loads • Minimize the distance. 19 July 2012 KLE College of Pharmacy, Nipani. 6
  • 7. Principles of material handling • The design of the container.e.g. shippers are used for storing finished bulk. & for raw materials as per the property of materials they are stored- plastic containers ( light weight containers) • Re-handling and back tracking of the materials should be avoided. • The materials handling service should not interfere with the production flow. 19 July 2012 KLE College of Pharmacy, Nipani. 7
  • 8. Classes of materials • Raw materials:- These are materials that are used in the product which is in an unprocessed condition. • Purchased Parts:- These are the items used in the assembly of the product. 19 July 2012 KLE College of Pharmacy, Nipani. 8
  • 9. Classes of materials • In-progress materials:- They are called ‘work in progress’ inventories. These goods require further processing. • Finished materials:- These are fully manufactured goods, inspected and ready for delivery to the customers. • Supplies:- These are consumable goods used in the process of manufacturing. 19 July 2012 KLE College of Pharmacy, Nipani. 9
  • 10. Functions of material management 19 July 2012 KLE College of Pharmacy, Nipani. 10
  • 11. Materials-Quality & Quantity • Four factors affecting the purchase of raw materials are 1) Quality :- The suitably of an item to accomplish the intended work. The raw materials should satisfy the following requirements. i. Efficiency of the material. ii. Cost and the shelf –life. iii. For equipments, power consumption and power requirement. 19 July 2012 KLE College of Pharmacy, Nipani. 11
  • 12. Quantity • From the inventory point of view, quantity standards are decided on the following parameters; i. Maximum inventory ii. Minimum inventory iii. Standard order iv. Reorder point 3) Price 4) Delivery Date 19 July 2012 KLE College of Pharmacy, Nipani. 12
  • 13. Value Analysis • Definition:- It is a systematic study of every element for it’s cost in a part, material or service to make certain that it performs it’s function at the lowest possible cost. • Benefits of value analysis:- i. Decrease in existing cost of the product or service. ii. Unnecessary expenditure is identified and eliminated. iii. Product value improves for new materials and processes. iv. More profits. 19 July 2012 KLE College of Pharmacy, Nipani. 13
  • 14. Value ratio Mathematical representation of the value can be done as Function Value = Total cost Reasons for unnecessary costs:- i. Lack of information ii. Lack of ideas iii. Changed circumstances iv. Wrong beliefs, habits and attitudes 19 July 2012 KLE College of Pharmacy, Nipani. 14
  • 15. Value Analysis Technique In this technique (n) number of questions are applied, like:- o what must I do? o What else does the item do? o What does it cost? o What else will the job do? o What will be alternative costs? 19 July 2012 KLE College of Pharmacy, Nipani. 15
  • 16. Purchasing Centralized :- the purchasing Decentralized:- different procedure of materials for department purchase their different department is done requirement seperately. together from one This is basically seen in purchasing department. large organizations. This is seen in small organizations. Advantages  Flexible purchasing system Advantages  Procurement is faster  Efficient system  Bargaining capabilities increased  Good raw material obtained at lower price 19 July 2012 KLE College of Pharmacy, Nipani. 16
  • 17. Vendor development The supplier or the person who sells the required materials or services for the production is known as a vendor. The purchase of raw materials/service from a specific vendor is known as the vendor development. There are four stages of vendor development:- 19 July 2012 KLE College of Pharmacy, Nipani. 17
  • 18. Four stages of vendor development Stage Name Development Survey stage Identifying the potential 1st sources of suppliers. Seeking information. Provisional vendors list. Enquiry stage Analysis of information in 2nd standard enquiry format. Accreditation, FDA approval, ISO certification. Personal visits. Negotiations and Quality control 3rd selection stage specifications, clarification, credit, quantity discounts. Experience and Performance appraisal, 4th evaluation stage Quality, delivery time. 19 July 2012 KLE College of Pharmacy, Nipani. 18
  • 19. 1) Survey stage The following sources are considered for information • Trade directories :- e.g. Yellowpages.eindiabusiness.com • Trade journals:- e.g. Pharmatimes • Telephone directories • Supplier’s catalogue • Salesmen Other ways are like interchanging of information with other companies, tracing of public tenders and advertisements in the press. 19 July 2012 KLE College of Pharmacy, Nipani. 19
  • 20. 2) Enquiry stage After getting the information of the suppliers, detailed analysis of the supplier is being carried out. A comparison is being made between the different suppliers on basis of the following points:- a. Technological competition, b. service competition, c. price competition, d. delivery time. 19 July 2012 KLE College of Pharmacy, Nipani. 20
  • 21. 2) Enquiry stage The following aspects can be verified by the first hand visit:-  Internal facilities of the vendor  Financial adequacy, stability and reputation of the vendor  Location of vendor’s factory  After sales service  Industrial relations 19 July 2012 KLE College of Pharmacy, Nipani. 21
  • 22. 3) Negotiation and selection stage • The vendors who clear the enquiry stage are selected and negotiations are being carried out with them. • The various aspects such as credit, quantity discount, quality specifications are being discussed. 19 July 2012 KLE College of Pharmacy, Nipani. 22
  • 23. 4) Experience and evaluation stage • The buyer evaluates and appraises the performance of the vendor. • The objective is to improve the performance of the vendors. Few ways of evaluating a vendor are:- o Categorial method o Weighted point method o Cost ratio method 19 July 2012 KLE College of Pharmacy, Nipani. 23
  • 24. Categorial method The buyer sets up some category on which the evaluation of the vendor is done. Specimen of supplier’s evaluation form is given below. Grading Factors Always Usually Seldom Never 9 8 7 6 5 4 3 2 1 0 Supplies are as per quantity selected Deliveries are on time Rigorous follow up is not necessary Willing to accommodate when production schedules are suddenly changed 19 July 2012 KLE College of Pharmacy, Nipani. 24
  • 25. Weighted point method Here the rating points are divided between quality, delivery and price. For eg quality – 50 points delivery- 30 points price – 20 points so total is 100 points. The rating can be obtained by following equation. 19 July 2012 KLE College of Pharmacy, Nipani. 25
  • 26. Weighted point method Quantity rating = (no. of lots accepted/ no. lots received) ×rating points Delivery rating = (no of lots delivered on time/ no of lots delivered) × rating points Price rating =(least offer received/ supplier’s offer) × rating points 19 July 2012 KLE College of Pharmacy, Nipani. 26
  • 27. Buying techniques Purchasing of material , machinery and services is done by purchasing department. For buying the material company has to pay up a price, the value that a seller sets on his goods in the market is called as the price of that good. Price is one of the greatest variables in the purchasing of material. 19 July 2012 KLE College of Pharmacy, Nipani. 27
  • 28. How is the purchasing done???? • Quotations :- It is a kind of an inquiry done to know whether the vendor can supply the desired material and at what price. • They are not the purchase order. They just contain all the details including freight, taxes and many other costs. • The highly used quotation techniques are • Spot quotations • Floating a limited enquire 19 July 2012 KLE College of Pharmacy, Nipani. 28
  • 29. How is the purchasing done???? • Spot quotations:- this is basically used for the small items not related to the technical purpose. The prospective buyer goes to the market and gets the quotations from the different suppliers. • Floating a limited enquire:- this method is used when the value of the purchase is small. In this technique the reliable vendors are called upon and asked to provide the quotations. 19 July 2012 KLE College of Pharmacy, Nipani. 29
  • 30. How is the purchasing done???? • Tenders:- It is a written letter or a published document that is aimed at finding the price for procuring certain materials. Tenders are invited from recognized firms. A few types of tenders are: # single tender # Open tender # Closed tender or limited tender 19 July 2012 KLE College of Pharmacy, Nipani. 30
  • 31. How is the purchasing done???? • Single tender:- It is invited from one reliable supplier. This kind of tender is floated only when the itms are required urgently. • Open tender:- Also known as ‘ press tender’. This is used when the value of item to be purchased is very high. It is used to locate more suppliers. In this tender procured, a small amount of the deposit money is taken from the supplier so that they do not withdraw from the submitted rates. 19 July 2012 KLE College of Pharmacy, Nipani. 31
  • 32. How is the purchasing done???? • Closed tender or limited tender (Negotiations):- It is done to arrive at the mutual understanding between the supplier/vendor and the buyer. 19 July 2012 KLE College of Pharmacy, Nipani. 32
  • 33. How is the purchasing done???? What’s the need for negotiation? @ prices are related to large volumes or to a large value. @ terms and conditions are required for large volumes. @ contract is desired for a longer period. @ variations in quantity to be purchase are possible. @ when supplies or services can be obtained from only one source. @ when no acceptable quotations are received from the other vendors. 19 July 2012 KLE College of Pharmacy, Nipani. 33
  • 34. How is the purchasing done???? Process of negotiations:- It is a kind of win-win situation. Both the parties try to benefit to the maxima through the negotiation. It is not a kind of bargaining but a mutual understanding between the two parties. 19 July 2012 KLE College of Pharmacy, Nipani. 34
  • 35. How is the purchasing done???? • Discounts:- They are cash concessions offered by the vendor to the buyer, in order to enhance the volume of the business opportunities. Reasons for offering discounts????? ! When there is a bulk purchase. ! When the bills are cleared immediately. ! And also to maintain the good rapo with the buyer Types of discounts:- 1) Volume contracts. 2) Deals 3) Discounts 4) Consignment terms 19 July 2012 KLE College of Pharmacy, Nipani. 35
  • 36. How is the purchasing done???? # Volume contracts:- This kind of discount is offered proportionate to the volume of material ordered. # Cash discount:- Cash discount is given on the basis of the time of the payment done by the purchaser. The normal credit period is 90 days. # Cumulative discount:- It is a method of offering the discount on the basis of actual purchases and appropriate to the quantity range in a year. 19 July 2012 KLE College of Pharmacy, Nipani. 36
  • 37. Purchasing cycle and procedure • The purchasing department of the company is responsible for the purchase of all the raw materials as well as the requirements. The following steps are followed in the purchasing cycle. 1) Recognition of need and receipt of requisition: The requisition includes the following information:- - Name - Quality and quantity specifications - Date by which material is required - Place at which material is to be delivered 19 July 2012 KLE College of Pharmacy, Nipani. 37
  • 38. Purchasing cycle and procedure 2) Selection of potential sources of supply 3) Making request for quotation 4) Receipt and analysis of quotations - material specifications and quality - price of the material - taxes - terms of payemeny - place of delivery - delivery period - gurantee period - validity of tender 19 July 2012 KLE College of Pharmacy, Nipani. 38
  • 39. Purchasing cycle and procedure 5) Selection of right source of supply 6) Issuing the purchase order 7) Follow-up of the order 8) Receipt of materials,reports and analysis 9) Checking and approving of vendor’s invoice for payment 10) Closing of completed order 11) Maintenance of record and file Purchasing cycle flow chart has been given in the following slide. 19 July 2012 KLE College of Pharmacy, Nipani. 39
  • 40. Spell out of specifications & Need recognition requirements Official requisitions Check specifications, Specifications Purchase prices/supplies file records Inquiry tender Select suppliers Supplier’s record Quotations & analysis prices and terms, negotiations, finalisation Purchase order for supply Suppliers’ acceptance Follow-up 19 July 2012 KLE College of Pharmacy, Nipani. 40
  • 41. • Contd …. Delivery of materials Checking of invoice Materials & reports, with purchase order analysis Payment made 19 July 2012 KLE College of Pharmacy, Nipani. 41
  • 42. Example of Materials and People Flow 19 July 2012 KLE College of Pharmacy, Nipani. 42
  • 43. Location of Stores :  Store should be located adjacent to the manufacturing area. It depends up on nature and value of items to be stored and frequency with which items are received and issued Objectives :  Minimum wastage of space  Maximum ease of operation  Minimum handling cost  Minimum other operational cost 19 July 2012 KLE College of Pharmacy, Nipani. 43
  • 44. Facilities of Store Inspection center Quarantine room Washing room Centralized weighing department Adequate space 19 July 2012 KLE College of Pharmacy, Nipani. 44
  • 45. Functions of stores General function :  Maintenance of Stock (materials and tools)  Maintenance of hygiene, sanitation, and pest control  Maintenance of material handling equipment 19 July 2012 KLE College of Pharmacy, Nipani. 45
  • 46. Functions of stores Specific functions :  Receiving & recording of raw materials  Quarantine storage – Sampling & approval by QC  Positioning & Storage  Issuing & recording of materials  Receiving & Dispatching of finished goods  Distribution Optional functions :  Dispensing, Maintenance of weights & measures 19 July 2012 KLE College of Pharmacy, Nipani. 46
  • 47. Material handling system Right Definition : Material handling uses the right method to provide the right amount of the right material at the right place, at the right time, in the right sequence, in the right position, in the right condition, and at the right cost. 19 July 2012 KLE College of Pharmacy, Nipani. 47
  • 48. Material handling system Involves handling, storing, and controlling material • The raw materials, in-process materials and finished goods are moved from one place to another in the plant. • Adds value through time and place utility • Impacts space requirement, profits, quality, safety, and productivity • On an average, 20% of production cost is spent on material handling system 19 July 2012 KLE College of Pharmacy, Nipani. 48
  • 49. Twenty Principles of Material Handling 1. Planning principle. Plan all material handling and storage activities to obtain maximum overall operating efficiency. 2. System principle. Integrate as many handling activities as is practical into a coordinated system of operations, covering vendor, receiving, storage, production, inspection, packaging, warehousing, transportation. etc. 19 July 2012 KLE College of Pharmacy, Nipani. 49
  • 50. Twenty Principles of Material Handling 3. Material flow principle. Provide an operation sequence and equipment layout optimizing material flow. 4. Simplification principle. Simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment. 5. Gravity principle. Utilize gravity to move material wherever practical. 19 July 2012 KLE College of Pharmacy, Nipani. 50
  • 51. Twenty Principles of Material Handling 6. Space utilization principle. Make optimum utilization of space . 7. Unit size principle. Increase the quantity, size, or weight of unit loads or flow rate. 8. Mechanization principle. Mechanize handling operations. 19 July 2012 KLE College of Pharmacy, Nipani. 51
  • 52. Twenty Principles of Material Handling 9. Automation principle. Provide automation to include production, handling, and storage functions. 10. Equipment selection principle. In selecting handling equipment, consider all aspects of the material being handled. 19 July 2012 KLE College of Pharmacy, Nipani. 52
  • 53. Twenty Principles of Material Handling 11. Standardization principle. Standardize handling methods as well as types and sizes of handling equipment. 12. Adaptability principle. Use methods and equipment that can best perform a variety of tasks and applications where special purpose equipment is not justified. 19 July 2012 KLE College of Pharmacy, Nipani. 53
  • 54. Twenty Principles of Material Handling 13. Dead weight principle. Reduce ratio of dead weight of mobile handling equipment to load carried. 14. Utilization principle. Plan for optimum utilization of handling equipment and manpower. 15. Maintenance principle. Plan for preventive maintenance and scheduled repairs of all handling equipment. 19 July 2012 KLE College of Pharmacy, Nipani. 54
  • 55. Twenty Principles of Material Handling 16. Obsolescence principle. Replace obsolete handling methods and equipment when more efficient methods or equipment will improve operations. 17. Control principle. Use material handling activities to improve control of production inventory and order handling. 19 July 2012 KLE College of Pharmacy, Nipani. 55
  • 56. Twenty Principles of Material Handling 18. Capacity principle. Use handling equipment to help achieve desired production capacity. 19. Performance principle. Determine effectiveness of handling performance in terms of expense per unit handled. 20. Safety principle. Provide suitable methods and equipment for safe handling. 19 July 2012 KLE College of Pharmacy, Nipani. 56
  • 57. Handling of materials must be performed  Safely  Efficiently  At low cost  In a timely manner  Accurately (the right materials in the right quantities to the right locations)  And without damage to the materials 19 July 2012 KLE College of Pharmacy, Nipani. 57
  • 58. Risks associated with improper handling • Increase in cost of raw material and finished products • Delay in production schedule and long production cycle • Waste of machine time and personnel time • Increase in in-process inventories • Damage or loss of material and employee safety liabilities • Employee frustration and reduced morale • Customers dissatisfaction 19 July 2012 KLE College of Pharmacy, Nipani. 58
  • 59. Selecting Material Handling System Systematic Approach 1. Define the problem 19 July 2012 KLE College of Pharmacy, Nipani. 59
  • 60. Selecting Material Handling System 2. Analyze the problem Observe activities Obtain layouts, flow patterns, schedules, etc. Obtain information on existing material handling equipment Analyze situation by Twenty Principles of Material Handling, and/or forms Can activities be combined, simplified, eliminated??? 19 July 2012 KLE College of Pharmacy, Nipani. 60
  • 61. Selecting Material Handling System 3. Identify possible solutions Organize meeting with: material handlers machine operators supervisors support engineers 4. Evaluate alternatives Meet again to rate alternatives 19 July 2012 KLE College of Pharmacy, Nipani. 61
  • 62. Material Handling Equipment Five categories: 1. Industrial trucks 2. Automated guided vehicles 3. Monorails and other rail guided vehicles 4. Conveyors 5. Cranes and hoists 19 July 2012 KLE College of Pharmacy, Nipani. 62
  • 63. Industrial Trucks Two basic categories: 1. Non-powered – Human workers push or pull loads 1. Powered – Self-propelled, guided or driven by human – Common example: forklift truck 19 July 2012 KLE College of Pharmacy, Nipani. 63
  • 64. Nonpowered Industrial Trucks (Hand Trucks) (a) Two-wheel hand truck, (b) four-wheel dolly, (c) hand-operated low-lift pallet truck 19 July 2012 KLE College of Pharmacy, Nipani. 64
  • 65. Powered Trucks Capacities from 450 kg up to 4500 kg Power sources include on-board batteries and internal combustion motors 19 July 2012 KLE College of Pharmacy, Nipani. 65
  • 66. Powered Trucks •Designed to pull one or more trailing carts in factories and warehouses, as well as for airport baggage handling •Powered by on- board batteries or IC engines 19 July 2012 KLE College of Pharmacy, Nipani. 66
  • 67. Automated Guided Vehicles An Automated Guided Vehicle System (AGVS) is a material handling system that uses independently operated, self- propelled vehicles guided along defined pathways in the facility floor • Types of AGV: – Driverless trains – Pallet trucks – Unit load AGVs 19 July 2012 KLE College of Pharmacy, Nipani. 67
  • 68. Driverless Automated Guided Train • First type of AGVS to be introduced around 1954 • Common application is moving heavy loads over long distances in warehouses and factories without intermediate stops along the route 19 July 2012 KLE College of Pharmacy, Nipani. 68
  • 69. AGV Pallet Truck • Used to move palletized loads along predetermined routes • Vehicle is backed into loaded pallet by worker; pallet is then elevated from floor • Worker drives pallet truck to AGV guide path and programs destination 19 July 2012 KLE College of Pharmacy, Nipani. 69
  • 70. Unit Load Carrier • Used to move unit loads from station to station • Often equipped for automatic loading/unloading of pallets and pans using roller conveyors, moving belts, or mechanized lift platforms 19 July 2012 KLE College of Pharmacy, Nipani. 70
  • 71. AGVs Applications 1. Driverless train operations - movement of large quantities of material over long distances 2. Storage and distribution - movement of pallet loads between shipping/receiving docks and storage racks 3. Assembly line operations - movement of car bodies and major subassemblies (motors) through the assembly stations 4. Flexible manufacturing systems - movement of work parts between machine tools 5. Miscellaneous 19 July 2012 KLE College of Pharmacy, Nipani. 71
  • 72. Rail-Guided Vehicles • Self-propelled vehicles that ride on a fixed-rail system • Vehicles operate independently and are driven by electric motors that pick up power from an electrified rail • Fixed rail system – Overhead monorail - suspended overhead from the ceiling – On-floor - parallel fixed rails, tracks generally protrude up from the floor 19 July 2012 KLE College of Pharmacy, Nipani. 72
  • 73. Overhead Monorail 19 July 2012 KLE College of Pharmacy, Nipani. 73
  • 74. Conveyor Systems • Large family of material transport equipment designed to move materials over fixed paths, usually in large quantities or volumes 1. Non‑powered : Materials moved by human workers or by gravity 2. Powered : Power mechanism for transporting materials is contained in the fixed path, using chains, belts, rollers or other mechanical devices 19 July 2012 KLE College of Pharmacy, Nipani. 74
  • 75. Conveyor Types • Roller • Skate‑wheel • Belt • In‑floor towline • Overhead trolley conveyor 19 July 2012 KLE College of Pharmacy, Nipani. 75
  • 76. Roller Skate‑wheel Belt Overhead trolley conveyor In‑floor towline 19 July 2012 KLE College of Pharmacy, Nipani. 76
  • 77. Cranes and Hoists Handling devices for lifting, lowering and transporting materials, often as heavy loads • Cranes – Used for horizontal movement of materials • Hoists – Used for vertical lifting of materials • Cranes usually include hoists so that the crane- and-hoist combination provides – Horizontal transport – Vertical lifting and lowering 19 July 2012 KLE College of Pharmacy, Nipani. 77
  • 78. Hoist Load 19 July 2012 KLE College of Pharmacy, Nipani. 78
  • 79. Bridge Crane Gantry Crane Jib Crane 19 July 2012 KLE College of Pharmacy, Nipani. 79
  • 80. Salvaging and Disposal of Scrap and Surplus The words ‘Scrap’ and ‘Surplus’ symbolize waste and to that extent these account for the loss of profits. Scrap is commonly used for waste of all kinds. 19 July 2012 KLE College of Pharmacy, Nipani. 80
  • 81. These occur for the following reasons:  Mistakes in procurement  Wrong planning decisions  Wasteful processes in production  Inevitable waste during the adjustment of the equipment  Overall absence of efficiency 19 July 2012 KLE College of Pharmacy, Nipani. 81
  • 82.  Disposal of scrap, surplus, recyclable, obsolete materials is one of the most important area of materials management, but often overlooked or considered minor.  Popular due to increased public awareness of environment, government legislation, better recognition of opportunities it offers in return. e.g. paper files and forms are recyclable item that can be sold to recycle company. 19 July 2012 KLE College of Pharmacy, Nipani. 82
  • 83. The following measure are adopted and monitored for handling scrap: 1. Controlling of surplus and scrap 2. salvaging or converting the waste for advantageous use. 3. Disposal of the surplus and scrap to the best advantage. 19 July 2012 KLE College of Pharmacy, Nipani. 83
  • 84. The production department primarily controls the first function by proper design, while purchase department handles the second and third functions. Waste materials in pharmaceutical industry: • Empty drums, packing materials, card boards, aluminium caps, bottles etc. these are non- recoverable rejects. • Spoiled materials during production. In a few instances, these may be recoverable. • Worn-out parts of equipments (examples are punches and dies), old equipment (due to expiry of life) and obsolete equipment (due to technology change). 19 July 2012 KLE College of Pharmacy, Nipani. 84
  • 85. Salvage : It is defined as the processing of materials (items) for advantageous use or disposal of company property, which is no longer economically useful in its present position. Salvage operation :  Waste materials are properly collected and stored at one place continuously, so that these can form a separate batch in production.  Recoverable materials are stored in a scientific way as other items stored. 19 July 2012 KLE College of Pharmacy, Nipani. 85
  • 86.  Materials are stored in terms of quality or size or specifications.  Waste is invested for suitability to recover or avoid them.  Salvaging operation are possible under the following conditions:  Evidences from laboratory tests and assays that the drug products meet all applicable standards of identity, strength, quality and purity.  Evidence from inspection of premises that the drug products and their associated packing were not subjected to improper storage condition, as a result of the disaster or accident. 19 July 2012 KLE College of Pharmacy, Nipani. 86
  • 87. Disposal Disposal of scrap, waste and surplus materials can be effected by several way :  Surplus material should be returned to the original supplier. Alternatively a customer who needs them should be explored.  As a social obligation, some material are defected or broken before selling them as scrap. 19 July 2012 KLE College of Pharmacy, Nipani. 87
  • 88. Disposal  Materials may be sold by inviting quotations from potential buyers or through various contracts such as fixed price contract, varying price contract, specific bids and negotiations. • It is worth considering that scrap like any other material represents money and to that extent it has a value. 19 July 2012 KLE College of Pharmacy, Nipani. 88
  • 89. Unit lode, Pelletization and Containerization  Unit load is a set of items (raw material, semi finished parts, finished product) to be move together, like:  A set of cartons on a pallet  A set of products in a container  In a unit load, parts are  In something (In a carton)  On something (On a pallet)  Grouped by something (wrapped, strapped) 19 July 2012 KLE College of Pharmacy, Nipani. 89
  • 90. Reasons for using unit loads in material handling Multiple items handled simultaneously Required number of trips is reduced Loading/unloading times are reduced Product damage is decreased (a) Wooden pallet, (b) pallet box, (c) tote box 19 July 2012 KLE College of Pharmacy, Nipani. 90
  • 91.  Pallets : Style and Size based on:  Shipping and receiving restrictions  Size and weight of items on the pallet  Space restrictions  Equipment used to move the pallet  Cost, supply, and maintenance  Aisle widths, door sizes, stacking heights 19 July 2012 KLE College of Pharmacy, Nipani. 91
  • 92.  Types of Pallets :  Materials used : • Plastic • Softwood • Steel • Hardwood • Aluminium • Paper 19 July 2012 KLE College of Pharmacy, Nipani. 92
  • 93. Containerization : Different types of containers are used according to the type of material. e.g Boxes, cartons, cases, sacks, bales, pallets, drums, barrels, crates, cable drums, machinery, and processed timber • Tank containers for bulk liquids and dangerous goods. 19 July 2012 KLE College of Pharmacy, Nipani. 93
  • 94. TRAINING AND DEVLOPMENT • Training and development may be defined as an attempt to improve current or future performance of employees through learning, usually by changing the employees attitude or increasing his/her skills and knowledge. 19 July 2012 KLE College of Pharmacy, Nipani. 94
  • 95. TRAINING AND DEVLOPMENT • Training and development program - Steps : I. Explain the trainee what is the job, how is the job done and why is it done (relevance). II. Show how the job should be done (demonstration). III. Allow the trainee to do the job (practice). IV. Follow up by explaining what was done correctly and what was done incorrectly. Correction always should be made as privately as possible (feedback). 19 July 2012 KLE College of Pharmacy, Nipani. 95
  • 96. TRAINING AND DEVLOPMENT • Training and development program – Methods : I. On-the job training II. Off-the job training 19 July 2012 KLE College of Pharmacy, Nipani. 96
  • 97. TRAINING AND DEVLOPMENT I. On-the job training : Majority of industrial training are on-the job training, because it is related to the productivity. On-the job training refers to methods that are applied at the workplace, while the employee is actually working. 19 July 2012 KLE College of Pharmacy, Nipani. 97
  • 98. TRAINING AND DEVLOPMENT II. Off-the job training : This method is commonly used for the training of employees. Off-the job training refers to methods that are applied away from workplace. 19 July 2012 KLE College of Pharmacy, Nipani. 98
  • 99. JOB ANALYSIS • Job analysis is defined as a process of collecting and studying information relating to the operations and responsibilities of a specific job. 19 July 2012 KLE College of Pharmacy, Nipani. 99
  • 100. JOB ANALYSIS • Process of job analysis : Defining uses of job analysis Information collecting Information processing Job description Job specification 19 July 2012 KLE College of Pharmacy, Nipani. 100
  • 101. JOB ANALYSIS • Uses of job analysis : • Personnel planning • Training and development • Work scheduling • Performance appraisal • Job evaluation 19 July 2012 KLE College of Pharmacy, Nipani. 101
  • 102. JOB ANALYSIS • Job Description : is defined as a combination of statement containing the work to be performed and the essential working conditions of a particular job. • Job specification : may be defined as a statement of human qualities and other desirable characteristics required for discharging the assigned job. 19 July 2012 KLE College of Pharmacy, Nipani. 102
  • 103. JOB ANALYSIS Job Analysis Job description Job specifications Job title Education Job place Experience Job summary Training Machines, tools and equipment Judgment Materials and forms used Initiative Working condition Responsibilities Hazards 19 July 2012 KLE College of Pharmacy, Nipani. Physical effort 103
  • 104. JOB DESIGN • Job design involves conscious efforts to organize tasks, duties and responsibilities into a unit to achieve objectives. • Job design involves three steps. – Specifications of individual tasks. – Specification of the methods of performing each tasks. – Conversion of tasks into specific jobs to be assigned to individuals. 19 July 2012 KLE College of Pharmacy, Nipani. 104
  • 105. JOB DESIGN • Mechanisms of job design : Understanding the nature of job is important, because it determines the skill requirement in performing a job. Skill variation, responsibility and growth Low High Enlargement and enrichment 19 July 2012 KLE College of Pharmacy, Nipani. 105
  • 106. Job enlargement  It involves performing of a variety of jobs or operations at the same time. It is mainly intended to enlarge the job horizontally.  It avoids monotony, as a result of high degree of specialization, but the basic nature of job remains same. Therefore, it has limited role in motivating employees. There is a need for up- gradation of authority and responsibility. 19 July 2012 KLE College of Pharmacy, Nipani. 106
  • 107. Job enrichment  It acts as an additional motivating factors to other models described earlier in job design. This factor attracted more attention, both in academic circles as well as in practice. Therefore, it requires a detailed study. 19 July 2012 KLE College of Pharmacy, Nipani. 107
  • 108. Job enrichment  Job enrichment is concerned with designing of job in terms of the following : • Work content provides greater variety. • Levels of knowledge and skills are higher. • More autonomy and responsibility in terms of planning, directing and controlling is given to workers for their own performance. • Work experience becomes meaningful. 19 July 2012 KLE College of Pharmacy, Nipani. 108
  • 109. BLUE AND WHITE-COLLAR JOBS • A position that involves mainly physical labor. With the decline in manufacturing and an increase in harmonization agreements, the term blue collar is now rarely used. • Blue collar refers to the blue overalls traditionally worn in factories in contrast to the white shirt and tie supposedly worn by an office worker, known as a white-collar worker. 19 July 2012 KLE College of Pharmacy, Nipani. 109
  • 110. LABOR WELFARE • Labor Welfare means working out things for the well-being of the labors. Knowing there wants and enabling them to fullfill there wants. • Labor welfare is the voluntary efforts of employer to establish within the existing industrial system, working and sometimes living and cultural conditions of the employee beyond what is required by law. 19 July 2012 KLE College of Pharmacy, Nipani. 110
  • 111. Advantages of material management • It eliminates unproductive handling of the materials like back-tracking, rehandling etc. • It reduces idle machine capacity and thus ensures better turnover on investment. • It reduces considerably the idle time of the workers. 19 July 2012 KLE College of Pharmacy, Nipani. 111
  • 112. Advantages of material management • The quality of the materials is also maintained through minimum human touches, elimination of breakages, etc. • Every inch of the factory space is properly utilized. • The issue of materials is also facilitated. • It helps in maintaining effective production planning and control. 19 July 2012 KLE College of Pharmacy, Nipani. 112
  • 113. Advantages of material management • Reduced operating costs and timely production. • Greater job satisfaction on the part of both the workers and the employer. 19 July 2012 KLE College of Pharmacy, Nipani. 113
  • 114. References • CVS Subrahmanyam; Pharmaceutical Product and Management, Published by- Vallabh Prakashan, Page no :- 260 – 282 • S.C. Saksena; Business Administration Management, Published by- Sahitya Bhawan, Page no :- 262 – 263, chapter 20. 19 July 2012 KLE College of Pharmacy, Nipani. 114
  • 115. 19 July 2012 KLE College of Pharmacy, Nipani. 115

Notes de l'éditeur

  1. Dept.of Pharmaceutics.