sawa M
sawa M
Material control; is the process of planning, organization and controlling the procurement,
storage and usage of materials so as to achieve objectives of efficiency and economy. Material
control consists of three levels as follows
I. Quantity control
II. Financial control
III. Quality control
Objectives of material control, the following are the main objective of material control;
Purchase of material; is the procurement of material, components, supplies required for use in
production and other departments of enterprises to run Smooth the organization activities
effectively and efficiency.
Objectives of purchasing;
The objectives of purchasing is to procure the material that required in the organization ensuring
materials are
a) Right quality; the right quality is that features and characteristics of the product or service
which can be purchased at the lowest cost to fulfill the needs or satisfy the intended
purpose.
b) Right Quantity; the excess purchases should be avoided. If result in overstocking which
will increase the holding cost and the purchasing of low level Quantity should be avoided
to avoid understocking so as to avoid frequently placing order.
c) Right time; this means exact time of delivery. It should be taken into account to ensure that
the material required delivered within the required time. The lead time should be
maintained external lead time and internal lead time.
d) Right price; the price should be reasonable, fair, competitive and affordable. Ideally
minimizing the profit, it should be fair to both buyer and seller.
e) Right source; source can be supplies for procurement of goods a contractors for
procurement of works and a services providers for procurement of services
The purchase department has many function in the organization. The following are the function of
the department.
I. To purchase the right quality of material in the right quantity at right price and at right time.
II. To receive the purchase requisition from the department which needs the material( User
department)
III. To select the supplier from whom a materials are to be purchased.
IV. To follow up the purchase order
V. To place the purchase the purchase order with the selected supplier.
Purchase Procedures; depending up on the size and nature of the operation the purchase procedure
may differ from organization to organization. However there is main steps involved in purchasing
procedure are as follows.
Objectives of storage
I. To ensure and effective and economize use of the available Storage, space and labor.
II. To protect stores from against pilfered, theft, deterioration, evaporation.
III. To identify and locate the stores without delay and issues stores immediately.
IV. To prevent overstocking and understocking of stores.
V. To ensuring uninterrupted supply of stores to the production and services department.
Documents Used in store; in handling store it is important to have the document that will be used
for the future reference or dealing with any disputes that will rise against the materials stored the
following are the document used in stores.
I. Purchase requisition note. This document prepared by the store keeper to the purchasing
officer for the materials requested or needed for use.
II. Bin card; This document used for recording the materials that are Received and issued in
the store, this document records the materials goes out to the store
III. Material return note; this document allows the unused materials to be returned to the store
from the production department or user department.
IV. Material transfer note; this document allows the materials to be transferred from one
location to another. Example at construction of IAA. When the material transferred from
PGD site to hostel site this document should be fulfilled.
V. Billed materials. It is of master requisition listing all the materials and parties necessary for
a particular or typical job or production run.
Material issue procedure; material coming- process of reviving demanded Lithe proven
Selecting Ames required and handling Him Ove
The following base documents are word for issue of materials to production department;
a) Material requisition Cur cores requisition) - is a document which is used to authorize and
records the issue of material from the store.
b) Bill of materials (material specification list) - is a list of standard quantities of all materials
required for a particular job or work order or a process.
Classification of materials;
1. ABC Analysis; the materials are grouped into three catenae’s Bering into values and
materiality of this materials
A-group: Represent the substantial amount of fund invested in materials on the group, the
maternal item in group are Critical to the function and operation of an organization and because of
this the inventory levels must be carefully monitored.
B-group: Are important to the firm but are not critical, ace for items. About 20% of all materials
C-Group: Are not that all important to the operation of the firm but call necessary. But c-group
take 10% of all inventory items.
2. Ammonals coding system.
Example
Cement. 001
Simba. 0011
Pc pipe. 0012
ls the optimum or the most favorable quantity that should be purchased each time the purchase
are to be made, EOQ is where the cost of carrying inventory is equal to the ordering costs and be
determined using three methods which is
I. Equation method.
EOQ = √2𝐷𝐶𝑜/𝐶𝑐
Where;
Re-order level; this provides amount when the economic Order Quantity Should be ordered. Is a
level at purchase order should be initiated for fresh Supplies
Minimum Stock level (min Stock level); This is maintained to prevent the stock outs, it is
essentially a safety or buffer stock which act as a Cu shim against stock out The level should be
maintained to ensure the stock do not drop down to this level of inventory.
Min stock level = Re-order level - [Average rate of Consumption X Average lead time)
Maximum Stack level (Max stock level); is the level of which the inventory should not exceed
to undergo overstocking or the uppermost amount of stock the company can maintain at the any
time. (Level at which stock should not be allowed to rise)
Max stock level = [Re-order level + ECG]-[mining Wage x minimum lead time]
Danger level; is the level below the minimum or safety stock level. It represent stage where
immoderate steps are taken for getting stock replenished, otherwise will result into production
Stoppage.
Average stock level; is the level where the stock should be maintained at the constant to ensure
not exceed or overstocking the balance levels.
In issuing the material it is hard to recertify the Value of closing stock and the cost of materials.
So this method should be used in pricing. The materials, the following are the method used in
pricing materials
I. First in first. Out (FIFO) method; this method used to price the inventory at the earliest
cost. This means that has unused materials closing stocks) are constituted by the goods
which were most recently purchased. The oldest cast are used first for accounting purpose.
II. Last in First Out (LIFO) Method; this method based on the assumption that goods that
received last are issued first, Cost of issue tend to be nearer current market prices because
it represent the cost of current purchases.
III. Simple Average prang method; this method based on the assumption that the identity
of materials when put on the stores is lost and materials are received in uniform loss of
some quantity.
Both costs of materials issued and closing stock tend to reflect actual cost
Weighted Average price / Method Weighted Average Cost method (WAC); this method is
based on the assumption that each issue of goods consists of due proportion of the early lost.
Stock level; means the quantity of goods inventory that a business has available at a given point
in time. Through stock level the business man help to ensure that the right amount of stock is
maintained to meet the customer demand without overstocking or understanding. The following
are the factors which must be considered in selling stock levels.
Lead time; the time it takes for four supplier to deliver your order. This factor is very important
to consider when we lead time by setting your records point to avoid stock outs.
Inventory optimization; this is the process of finding the optimal balance between inventory
cost and service level. Also it can help you to optimize your inventory using tools like inventory
analysis and inventory classification.
Reorder point; the minimum level of inventory that determine when you should Re-order by
setting your Reorder quantity you must consider both customer demands and lead time
Safety stock; the extra stock you keep on hand to avoid stock outs in case of an expected demand
spike or mishap also maintain a buffer stock to account for uncertainties in demand and supply.
Order Quantity; determine the optimal order quantity using method like economic Order
Quantity which helps minimize total inventory costs by balancing ordering and holding costs.
Therefore; by considering this factors business can set appropriate stock level that their
operational goals and customer satisfaction.
QUESTION 3.1
Maximum stock level = (Pre-order level + EOQ)-(minimum usage × minimum lead time)
But,
EOQ =5,000units
From,
Maximum stock level = [Re-order level+ EOQ] - (minimum usage × minimum lead time)
From,
Minimum stock level= [Re-order level - (normal usage × average lead time]
But,
Now
From,
10,000 units.
From,
But,
1 week=7 days
? =200days
7days =200weeks.days
7days =7days
28.5weeks
Now,
Inventory re-order level=30,000units/ weeks × 28.5 weeks
From, Minimum inventory level= Re-order level - (normal usage ×average lead time)
Minimum inventory level= Re-order level (normal usage ×average lead time)
But,
Normal usage=5000+30,000/2
Normal usage=17,500units/week.
1week= 7days
? =150days
7days= 150week.days
7days= 7days
Now,
=855,000units-367,500
But,
Annual demand (D) = normal usage × number of weeks in year
Normal usage = 17,500units/weeks
Number of weeks in year=52weeks
Annual demand (D) =17,500units/week ×52weeks
D=910,000units
Co =TZS 360,000 per order
Cc =5/100×5000×52 weeks=13000TZS.
Now,
From,
Economic order quantity (EOQ) =√2DCo/Cc
(EOQ)=√2×910,000×360,000/13,000
(EOQ)=50,400,000 units
Economic order quantity will be 50,400,000units.
From,
Maximum inventory level= [Re-order level + EOQ]-[minimum usage ×minimum lead time]
i. Performance measurements.
v. Bench marking.
i. Data dependency
QUESTION 3.4
FIFO METHOD ON JUNE
Date Receipt (000) Issue (000) Balance (000)
Details Q UP V Q UP V Q UP V
Opening 100 15 1,500
1st /06 Received 200 20 4,000 300 5,500
30th/06 Received 100 30 3,000 400 8,500
30th/06 issued 100 15 1,500 300 7,000
30th/06 issued 170 20 3,400 130 3,600
(iv)
SIMPLE AVERAGE PRICE METHOD FOR WEMA CO.
Date Receipt Issue Balance
Details Q UP V Q UP V Q UP V
12/03 Received 200 60 12,000 200 60 12,000
22/03 Received 400 80 32,000 600 44,000
31/03 Received 400 100 40,000 1000 84,000
01/04 issued 300 80 24,000 700 60,000
(v)
REPLACEMENT PRICE METHOD FOR WEMA CO.
Date Receipt Issue Balance
Details Q UP V Q UP V Q UP V
12/03 Received 200 60 12,000 200 60 12,000
22/03 Received 400 80 32,000 600 44,000
31/03 Received 400 100 40,000 1000 84,000
01/04 issued 300 100 30,000 700 54,000
QUESTION 3.6 (i)
FIFO METHOD FOR WEMA CO.
Date Receipt Issue Balance
Details Q UP V Q UP V Q UP V
12/03 Received 200 60 12,000 200 60 12,000
22/03 Received 400 80 32,000 600 44,000
31/03 Received 400 100 40,000 1000 84,000
01/04 issued 300 60,80 20,000 700 64,000
(ii)
LIFO METHOD FOR WEMA CO.
Date Receipt Issue Balance
Details Q UP V Q UP V Q UP V
12/03 Received 200 60 12,000 200 60 12,000
22/03 Received 400 80 32,000 600 44,000
31/03 Received 400 100 40,000 1000 84,000
01/04 issued 300 100 30,000 700 54,000
(iii)
WEIGHTED AVERAGE METHOD FOR WEMA CO.
Date Receipt Issue Balance
Details Q UP V Q UP V Q UP V
12/03 Received 200 60 12,000 200 60 12,000
22/03 Received 400 80 32,000 600 44,000
31/03 Received 400 100 40,000 1000 84,000
01/04 issued 300 84 25,200 700 58,800
QUESTION 3.7 (a)
(i)FIFO METHOD
Particular Q UP V Q UP V Q UP V
300
Particular Q UP V Q UP V Q UP V
250
(iii) WEIGHTED AVERAGE METHOD
Particular Q UP V Q UP V Q UP V
b) Two methods;
ii. Replacement
QUESTION 3.8
Data given
= 9000 units
= [Re-order stock level + Re-order quantity] - [minimum usage * minimum lead time]
=10,800units
= 900units - (600 * 8)
= 9,000units - 4,800units
= 4,200units
=15,000/2
=7500units
Data given
Required;
i). determining ordering size that minimize annual tatal cost (EOQ)
= √2×3,600×200/ 20%×5
= √1,440,000
= 1,200 units
The ordering size that minimize annual total cost is 1200 units.
= 18,000 Tsh
From Annual possession cost = acquisition cost + carrying cost + Ordering Cost
= 3,600units × 1,200units
n =3
= 600 Tsh
Where Carrying Cost = Average of Economic order quantity × Carrying Cost per unit
= 600 Tsh
= 19,200 Tsh
QUESTION 3.10
i. EOQ
From,
EOQ= √2DCo/Cc
But,
Required EOQ=?
From
EOQ=√2*6000*120/2
EOQ=346.4 units
From,
90 units/week * 6weeks
From,
Minimum stock level= Re-order level - (normal usage * average lead time)
= 540 - (60 * 5)
= 540 - 300
= 240 units
Note: 5% cash discount on list price, net of trade discount, if payment is made within 20days
QUESTION 3.13
Data given
Re- order quantity 2,000unity
Re-order level 500unity
Solution
BIN CARD XYZ 444 FOR NJIRO MANUFUCTURING COMPANY
Dates Units ordered and received Unit issues Balance unit
Jan 02,2022 Opening balance 3,000
Jan 08,2022 - 2,000 1,000
Jan 12,2022 - 600 400
Jan 16,2022 2,000 - 2,400
Jan 18, 2022 - 2,500 (100)
Jan 20,2022 2,000 - 2,100
Feb 04,2022 - 2,100 000
Feb 15,2022 - 1000 (1000)
Feb 20,2022 2000 - 1000
Feb 24,2022 - 3,000 (2000)
March 03,2022 - 1,200 (3,200)
March 07, 2022 2,000 - (1,200)
March 13,2022 - 800 (2,000)
March 18,2022 2,000 - 000
March 21,2022 - 1,500 (1,500)
A = 2,000 L = (1000)
B = 2,000 M = 1,000
C = 2,000 N = (20000)
D = 2,000 P = (3,200)
E = 2,000 Q = (1,200)
F = 1,200 R = (2,000)
G = 400 S = 000
H = 2,400 T = (1,500)
I = 100
J = 2,100
K = 00