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ACKNOWLEDGEMENT
I wish to express my gratitude to all those individuals with whom, I interacted and
gained knowledge, insight and thoughts while preparing this project report. First of
all, I am grateful to the Mr. Dave – HR Manager, JK Tyres and Industries Ltd. for
would like to thank Shri N. P. Sarkar, Head Logistic department, for their co-operation
I also take this opportunity to thank the all the staff of JK Tyres and Industries Ltd.
when required.
Last but not least, I am thankful to my parents and friends for their support,
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Management of Business Logistic
PREFACE
There are always two sides of knowledge, practical as well as theoretical. Practical is
the path through which one can reach his destination. But it is essential to have clear
ideas to reach that destination and that is what theoretical knowledge means. In short,
Experience makes man perfect. By facing practical situation, one can get new ideas.
can make use of whatever he or she gets from his or her Academic background. Since,
practical situation, how a firm manages its logistic activities. I have tried to put my
best effort to complete this task on the basis of skill that I have achieved during my
study in the institute. I have tried to put my maximum effort to get the accurate
statistical data. However I would appreciate if any mistakes are brought to me by the
reader.
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Management of Business Logistic
TABLE OF CONTENT
Chapter No. Content Page No.
Executive Summary
1 Objective and Research Methodology
2 Theoretical background of logistic management
Definition of Logistic
Logistical Competency
Mission of logistic management
Five Logistical Pillar
Types of logistics
3 Company Profile
4 Logistic Management of Ceat Ltd.
Customer Segment
Raw Material Management
Forecasting
Manufacturing process
Machinery Details
Distribution Management
Transportation system
Information System
Material Planning Requirement
Just In Time Supplier
Measures for cost cutting
Employee motivation factor
5 Recommendation
6 Bibliography
EXECUTIVE SUMMARY
market share with the customer satisfaction through improved internal and external
trading entities. Hence the concept of Logistics gains a considerable importance in the
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Management of Business Logistic
material, service, information and capital flows. Logistics systems have received
considerable attention in the last 10 years as they constitute one of the cornerstones in
the design and control of production systems and the modeling of supply chains.
The supply chain process perspective has a strategic importance that provides great
In this project, a brief analysis on the process of Logistic Management adopted by one
of the top tyre manufacturing company in India namely JK Tyres and Industries Ltd.
transportation is studied in detail. The required data has been collected from the
industry records and company personnel. Efforts have been made to analyze the
CHAPTER -1
OBJECTIVE AND RESEARCH METHODOLOGY
Logistics is inevitable in the future and essentially the management policy also has a
significant role in the future of world. It is viewed as the competency that links an
enterprise with its customers and suppliers. The customer in today’s marketplace is
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Management of Business Logistic
more demanding, not just of product but also of services. In today’s marketplace the
order winning criteria are more likely to be service based then product based.
Logistics Management can provide a multitude of ways to increase efficiency and
productivity and hence contribute significantly to reduce unit costs. The scope of
logistic spans the organization, from management of raw material through to the
delivery of final product. If the company’s’ logistic management is effective, it can
get right good to the right place at least cost.
◈ OBJECTIVES OF STUDY
◈ RESEARCH METHODOLOGY
RESEARCH DESIGN
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Management of Business Logistic
◈ LIMITATION
1) This project is restricted to study purpose only and can be used keeping in
view the object that is made for.
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Management of Business Logistic
CHAPTER -2
THEORETICAL BACKGROUND OF LOGISTIC
MANAGEMENT
Definition of logistic
The word “logistic” is derived from the Greek word “logistike”, meaning “the science
of computing and calculating” (Practical Mathematics). In ancient times logistics
involved the practical art of moving armies engaged in combats. Since that time
logistics has come to imply moving men and material on war footing to achieve
desired results.
Logistics in the sense of Physical Distribution first appeared in the academic literate
in early 1990’s but it was only during World War II that logistics developed and got
more attention. After World War II, Logistics was transferred in to industry and
developed as industrial logistics or business logistics.
Logistics is concerned with getting the products and services where they are needed
and when they are desired. It is difficult to accomplish any marketing or
manufacturing without logistical support.
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Management of Business Logistic
Logistical competency
Competency is the ability to perform a function. Logistical competency is the ability
of the firm to perform logistical function effectively and efficiently.
In achieving logistical competency the firm should coordinate all functions well.
Network design should integrate the need of information, transportation & inventory.
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Management of Business Logistic
In a tour made by a product from a raw material stage (Supplier) to the manufacturing
firm to the point of consumption by the customer, logistics encompasses a wide range
of functional areas like transportation and material handling required for movement of
the material, Storing and Warehousing for storage, Information flow etc.
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Management of Business Logistic n
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Management of Business Logistic
Inventory
Warehousing, Material handling and packaging
Network design
Logistical efficiency is directly dependent upon network design. In integrated
logistical management manufacturing plants, warehouse, and retail stores are included
to market firm’s products. To prepare a proper network design, we must decide how
many of each type of facility are required, their geographical locations, and the work
to be performed at each one of them, the transport cost involves etc. In specific
situation, a particular operation could be outsourced to specialists in that field. But at
the same time, regardless of who does the actual work, all facilities must be managed
as an integral part of the firm’s logistical network.
Information
The importance of information is extremely essential for logistical performance.
Accurate information can improve logistical performance. Today’s technology enables
anyone to obtain information required for logistical performance. At the same time, if
quality information is not available, it can create countless operational problems.
Forecasting and order management are two areas of logistical work that depend on
information. The logistical forecast is an effort to estimate future requirement. The
forecast is used to guide the positioning of inventory to satisfy anticipated customer
requirements. Logistics manger’s track record in forecasting is not impressive.
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Management of Business Logistic
Therefore, one of the main reasons managers use information to achieve positive
control of logistical operations is their desire to replace forecasting in accuracy with
faster response to customers requirements. Control concepts such as just-in-time
(JIT), quick response (QR) and continuous replenishment (CR) represent approaches
to positive logistical control. One of the main jobs of logistics mangers is to plan and
implement their firm’s strategy regarding the desired combination of forecasting and
operational control.
The more efficient the design of a firm’s logistical system, the more sensitive it is to
information accuracy. Finely tuned time-based logistical systems have no excess
inventory to accommodate operational errors because safety stocks are held to a
minimum. Incorrect information and delays in order processing can cripple logistical
performance. Information flow renders a logistical system dynamic. Thus, quality
and timeless of information are key factors in logistical operations.
Transportation
In involves physical movement of inventory to and from various geographical points.
Transportation cost is visible i.e it can actually be calculated. This is one of the
reasons why attention is paid to this cost from the point of view of increasing
efficiency at reduced cost. Due to this, almost every organization has appointed
managers to handle transportation.
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Management of Business Logistic
But, from the logistical management view point, the three fundamentally important
factors for efficient performance of transportation of goods are:
Cost: The cost of transport is the payment for movement between two
geographical locations and expenses related to administration and maintaining
in-transit inventory. Logistical system should be designed to utilize
transportation that minimizes total system cost. This means that the least
expensive transportation does not always result in the lowest total cost of
movement.
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Management of Business Logistic
Inventory
The inventory requirement of a firm depends on the network structure and the desired
level of customer service. Theoretically, a firm could stock every item sold in a
facility dedicated to service each customers. Few business operations could afford
such a luxurious inventory. The objective is to achieve the desired customer service
with the minimum inventory commitment because the risk and total cost would be
prohibitive. Excessive inventories may compensate for deficiencies is basic design of
a logistic network and to some degree inferior management. However, excessive
inventory used as a crutch will ultimately result in higher than necessary total
logistical cost.
Logistical strategies are designed to maintain the lowest possible financial assets in
inventory. The basic goal of inventory management is to achieve maximum turnover
while satisfying customer’s commitments. A sound inventory management policy is
based on five aspects of selective deployment, customer segmentation, product
requirement, transport integration, time based requirement and competitive
performance.
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Management of Business Logistic
core market for an enterprise. The company must keep inventories ready at
hand to meet demands of these customers.
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When warehouses are required in a logistical system, a firm can choose between
obtaining the services of a specialist and operating its own facility. The decision is
broader than simply selecting a facility to store inventory, since many activities
essential to overall logistical process are typically performed while products are
warehoused. For examples sorting, Sequencing, order selection, transportation
consolidation.
To facilitate handling efficiency, products in the form of cans, bottles, or boxes are
typically combined into larger units. The initial unit, the master carton, provides two
important features. First, it serves to protect the product during the logistical process.
Secondly, it facilitates ease of handling by creating one large package rather then
multiple small ones.
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TYPES OF LOGISTICS
1. Military Logistics
2. Business Logistics
3. Service Logistics
4. Service Response Logistics
5. Event Logistics
6. Third Party Logistics
7. Fourth Party Logistics
8. Inbound Logistics
9. Outbound Logistics
10. Reverse Logistics
1. MILITARY LOGISTIC
Logistics: (military definition) The science of planning and carrying out the
movement and maintenance of forces… those aspects of military operations that deal
with the design and development, acquisition, storage, movement, distribution,
maintenance, evacuation and disposition of material; movement, evacuation, and
hospitalization of personnel; acquisition of construction, maintenance, operation and
disposition of facilities; and acquisition of furnishing of services.
Military Logistics: The design and integration of all aspects of support for the
operational capability of the military forces and their equipment to ensure
readiness, reliability and efficiency.
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Management of Business Logistic
2. BUSINESS LOGISTICS
BUSINESS LOGISTICS: It is the part of the supply chain process that plans,
implements and controls the efficient flow and storage of goods, services and related
information from point of origin to point of use or consumption in order to meet
customer requirements.
3. SERVICE LOGISTICS
While the traditional logistics concept looks at product movement, service response
logistics addresses the coordination of nonmaterial activities to fulfill services
efficiently and effectively. In fact, physical logistics and service response logistics are
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Management of Business Logistic
mutually dependent. Many service response logistics activities relate closely to the
logistics activity of communication and information.
5. EVENT LOGISTICS
The network of activities, facilities and personnel required to organize, schedule and
deploy the resources for an event to take place and to efficiently withdraw after the
event.
Third party logistics is the activity of outsourcing activities related to Logistics and
Distribution. The 3PL industry includes Logistics Solution Providers (LSPs) and the
shippers whose business processes they support. Companies opt for Third Party
Logistics for the following reasons:
In short, A Third Party Logistics firm may be defining as an external supplier which
performs all or part of the company’s logistics functions.
Fourth party logistics provider is a supply chain integrator that assembles and
manages the resources, capabilities, and technology of its own organization with those
of complementary service provider to deliver a comprehensive supply chain solution
to the client.
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Management of Business Logistic
Step 1: Reinvention:
At this level, the overall business strategy is aligned with supply chain strategy to
reengineer the supply chain of the participants.
Step 2: Transformation:
Here the focus is on coordinating specific supply chain functions such as sales and
operations planning, distribution management, procurement strategy, customer
support and supply chain technology, with the aid of process and organizational
changes, T & D, information technology, etc. as applicable.
Step 3: Implementation:
The implementation is done on the basis of recommendations made at the earlier two
levels and the transition is put across to the 4PL delivery team, taking special care to
consider the dimension of human resources and organizational change.
Step 4: Execution:
A 4PL provider’s scope of responsibility also includes operational responsibility for
numerous supply chain functions, besides the traditional transportation management
and warehousing operations logistics outsourcing.
8. INBOUND LOGISTICS
Activities associated with receiving, storing and disseminating inputs to the product
such as material handling, warehousing, inventory control, vehicle scheduling and
returns to suppliers.
This take care of the various activities the firm needs, to procure material and parts
from its vendors. It takes care of the procurement cycle. The task involves
Sourcing
Order placement
Transportation
Receiving
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Management of Business Logistic
In inbound logistics, factors like required delivery time, size of shipment, mode of
transportation, value of material, inventory levels etc. have to be planned. For E.g. A
breads manufacturer will buy flour in bulk, as bulk purchases will be cheaper, while
an automobile manufacturer wanting high priced items may prefer fewer inventories
to bulk purchases, Again a company dependent on coal will stock more in summer as
coal is preferentially delivered to thermal power stations in India in summer.
9. OUTBOUND LOGISTICS
Activities associated with collecting, storing and physically distributing the product to
the buyers (Physical Distribution Cycle). It includes distribution of finished goods,
order processing, warehousing, material handling, delivery vehicle operations,
scheduling, shipping etc.
Reverse Logistics deals with storage and movement of material that flows from the
end customer back to the seller or supplier. This includes defective, containers and / or
packaging material. Reverse logistics is also known as environmentally responsible
logistics as it helps to recycle unwanted material (boxes, bottles). In soft-drink trade,
empty bottles are to be returned for re-use.
Reverse logistics may be defined as a process of moving goods from their place of use
to their place of manufacture for reprocessing, refilling, repairs of waste disposal. It is
a planned process of goods movement in the reserve direction, done in an effective
and cost efficient manner through an organized network.
Recycling: The primary goal of the reverse logistics system (RLS) is to move
products or materials backward through the distribution network.
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IV. Returning the product to the market place. The replacement process cannot be
successfully completed without an effective reverse logistics system.
CHAPTER -3
COMPANY PROFILE
Vision
To be amongst the most profitable tyre companies in India by 2016 through:
Current mileage:
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Management of Business Logistic
Network of 34 regional offices, 7 Zones, over 3,500 dealers and more than 100
C&F agents
Co.’s tyres, tubes and flaps are renowned for their superior quality and durability, and
are recognized as being ‘born tough’.
Ceat offers the widest range of tyres to all user segments, and manufacture world-
class radials for all Indian vehicles including:
Ceat also markets tubes and flaps, which are outsourced from 7 to 8 units.
Ceat enjoys long-standing business tie-ups with major OEMs including TATA Motors,
Ashok Leyland, Mahindra & Mahindra, Maruti, L&T, Eicher, Swaraj Mazda,
Caterpillar, Bajaj Tempo, Piaggio, Hero Honda, HMSI (wholly owned subsidiary of
Honda Motors, Japan) and TVS Motors.
Ceat is the first and only Indian tyre company to be awarded the ISO/TS 16949:2002
certification, by TUV, a reputed certification body, based in Netherlands
Products
CEAT manufactures largest range of tyres in the industry which incorporate both
cross-ply and radial technology. The range of tyres covers virtually all user segments
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– from giant earthmovers to specialty tyres for scooters and motorcycles. The
company also markets tubes and flaps.
CHAPTER -4
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◈ Customer Segment
JK Tyre
Divisional JK Tyre
Distribution
Centre
Dealers
C&F
Customers
Dealers
Customers
Directly supplied means supplying the finished tyre without storage to the potential
customer. Company supplies directly to Tata motors, Ashok Leyland, Mahindra and
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Management of Business Logistic
Mahindra, L&T, Eicher, Swaraj Mazda, Bajaj Tempo, Hero Honda and TVS motors
and many more.
Whereas, O.E.M godown is a godown where the finished tyres are stored and supplied
as per the requirement of the customers. OEM godown is only for few customers, i.e.
O.E.M godown supplies to Maruti.
2. Export:
JK Tyres Company export small as well as big tyres to the foreign country i.e. In
England, USA and many other countries. Firstly, company sends finished tyres to the
Divisional Distribution centre and from there, it goes to clearing and forwarding agent
{C&F}, and then it is placed at dealer’s location and finally reaches to customer. But,
JK tyres’ job is till the C&F, because company gets the payment from C & F agent.
Reverse logistic deals with storage and movement of material that flows from the end
customer back to the seller or supplier.
Stage-I
Customer:
Customer sent the destroyed tyres to the dealer. From there, company picks up the
damaged tyres and give the replacement of tyre as per the date of purchase by the
customer.
Stage-II
Dealer:
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Dealer collect the bad tyres form that customer and the send it to JK tyres regional
office. There are 30 regional offices which look after the reverse logistic system.
Stage-III
JK Tyres’ Company or manufacturing plant:
Company receives the destroy tyres form the regional office and then bad tyres are
send for the recycling process and from that new tyres are manufactured. Company
sends that new tyres to the dealer and dealer give the finished tyre to that customer
who brought the bad tyre to the dealer place.
This process goes again and again for the replacement of JK Tyres
JK Tyres’ Company has Material suppliers from within the country as well as from the
foreign countries.
Material Suppliers
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For Rubber:
Material supplier
(Rubber)
Domestic International
Kerala Indonesia
[Cochin]
Thailand
Malaysia
International suppliers are from Indonesia, Thailand, Malaysia and others countries.
For Fabric:
Fabric is also procured form domestic as well as International supplier.
In Domestic, procurement of Fabric is from SRF fabric.
In International, suppliers are from china, Malaysia, Thailand and other
countries.
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Carbon
Copper wires
Quality checking
Quality checking is different for finished tyre from that of raw material
If the company satisfied about the quality of raw material then the material move
forward for the production process. But, if the company not satisfied about the quality
of the raw material then the company contacts the supplier about the quality and
returns the goods to the supplier plant. For this the company also charges the penalty
on supplier, because of supplier bad quality of rubber, it affect the production process
or smooth flow of raw material in process.
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Management of Business Logistic
On the basis of this, the tyre quality is checked by the company and forwards the tyre
as per this available checking information.
In JK Tyre, Lead time is different for domestic and for international supplier
In domestic supplier of raw material is on daily basis. Company gets the raw
material from Kerala (Cochin) on daily basis
In JK Tyre, Reorder level has done on the basis of price effect i.e. availability of
raw material at cheap rate whether it is domestic or international.
For ex: - If Domestic supply i.e. in Kerala the price of rubber cost to Rs.180 with the
good quality whereas the same quality of rubber cost in Import is at Rs.126. Then the
company prefer to Import rather than from Domestic supplier.
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E.g. when a customer order is received requesting 80 units of product A and 20 units
of product B, the order contains 100 cases and two lines. If there are only 75 units of
product A available and all 20 of product B, the case fill would be 95% [ (75 +20) /
(80+20) ] and the line fill would be 50% (1/2).
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◈ Forecasting:
Most of the important business decisions involve some degree of uncertainty and
risk. Outcome of such decision cannot be predicted accurately. Forecasting is
technique used to reduce such uncertainty. It involves predicting future economic
conditions and estimating their impact on the business. Forecasting can be applied to
following areas:
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For ex: - Sales forecasting for the Financial Year April 2010 to March 2011, they will
conduct their forecast on Jan 2010 or Feb 2010
Steps in forecasting:-
Sales Forecast (Yearly)
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Company conducts the budget plan on every 24th of a month which will be applicable
for next month. It considers the following cost:
Raw material
Inventory cost
Material cost (it considers 70% of total cost)
Conversion cost (Rupee/unit)
Conversion cost means the cost which is required to convert the raw material to
finished tyres.
Conversion costs from raw material to finished tyre are
Power 10%
Employee cost 65%
Fuel 10%
Remaining 15% of conversion cost goes to preliminary expenses
Company Review the plant in first week of the month and again they do MRP
(MATERIAL REQUIREMENT PLANNING) and change the requirement as per the
plan and this plan is followed throughout the month.
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After Sales Forecasting, Company does Capacity Forecasting in that both plant
Bhandup as well as Nashik plant & Outsource, Forecast their capacity and find the
problem and suitable measures for fulfillment of Market demands.
Self Forecasting
Self Capacity
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From self forecasting they also determine their self capacity. If more requirements
occur they expand or enhance their capacity as per their ability of plant and outsource.
While determining the self capacity the individual plant and outsource find their self
capacity problem such as
Capacity problem
Labour absenteeism
Machinery capacity
Manpower requirement
JK Tyres’ manufacturing plant mostly depend on the manual labour and skilled
worker requirement, because of the non-availability of labour the production process
of a company will effect and it ultimately affect the market demand of company tyre.
There is less availability of manpower during April, May, June or during the Festival
time.
From here the company gets the exact capacity of plant and outsources for fulfillment
the market demand.
◈ Manufacturing Process
Component of Tyres
Thread
Side wall
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Chaffer
Band (fabric)
Bead (copper wire)
Proportion of bead = 10/6 rubber wire layer i.e. form a layer through using 10 time
rubber and 6 time wire.
Beads: It made upon high tensile steel wire. They anchor the tyre to the rim. Bead is
usually coated with Bronze or Brass coating for achieving adhesion with rubber.
Thread: It is made of rubber compounds designed to give high mileage, together with
good traction on wet and dry roads. Since there is a conflict between these
requirements, thread compounding uses a combination of rubbers and blacks designed
to give the best compromise.
Sidewall: Protects the tyre carcass and use compounds which give resistance to
cutting and cracking.
Chaffer: Protects the tyre beads against the rim. They can be made of rubberized
fabric or hard rubber compound.
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RMS
(Raw Material Storage)
Bias Cutting
Extruder Dept Dept
(Treads)
Tyre Building
Curing Dept
Molding
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Bead department makes Bead which is made up of copper wire and rubber.
Mixing department makes the tread through mixing rubber, carbon, oil and
chemical.
Cobalco department makes chaffer and bend which is made through the proportion
of fabric and rubber.
Calendar: The raw carcass materials made of textile or steel are coated with rubber.
This is done by passing them through a machine called a Calender, which has a series
of rollers in a stock, normally four. The rollers are called boles. The fabric passes
between the middle rollers and rubber is fed from above and below. The thickness of
the rubberized fabric is controlled by the gap between the rollers. The gap is called the
nip.
Extruding: The profiled slabs of rubber which go to make up the tread and sidewalls
of the tire are produced using an extruder. This machine forces the green rubber
through a die to give the required shape.
Assembly: All the components were assembled together in a tyre building department
where a tyre is made which is called as Green Tyre. Green Tyre is not a finished tyre.
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Curing: The green tyres are molded in a curing machine. The tyre is cured with high
pressure hot water inside the butyl bladder. This has replaced steam as the curing
medium, since pure steam at the pressures required would give too high temperature
for an even cure. The mold sidewall assembly is fixed to steel plates which are heated
by steam.
Finishing: After curing, the tyres pass to the finishing dept., where they are inspected
for defects after which they are run on balance machines and the heavy spots marked.
Then the tyre undergo to the other uniformity controls on a force variation machine.
◈ Warehousing
Warehousing is that part of a firm’s logistics system that stores products at and
between point- of- origin and point of consumption, and provides information to
management of the status, condition and disposition of items being stored.
A warehouse is a point in the logistics system where a firm stores or holds raw
materials, semi- finished goods, or finished goods for varying periods of time. It
creates time utility for raw material, industrial goods and finished products. The
proximity of market-oriented warehousing to the customer allows a firm to serve the
customer with shorter lead times. This warehousing function continues to be
increasingly important as companies and industrial use customer services as a
dynamic, value-adding competitive tool.
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Capacity
(250 Metric Ton)
Bhandup Nashik
Plant Plant
For
For
Finished
Raw
Material
Goods
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Interport Goods
Bhandup Warehouse:
It is situated near the manufacturing plant of Bhandup
It has the capacity of storing 250 metric tones of raw material
It is owned by company himself
Bhiwandi Warehouse:
It is the private owned warehouse
It is at the mid of Bhandup and Nashik plant
It is also store the goods which come for replacement/recycling work
Panvel Warehouse:
It is privately owned warehouse
It has the capacity of storing 2000 metric tones, but it has capacity to do
expansion or enhance its capacity if required by company
It stores import of raw material which comes from China, Thailand, Malaysia,
Indonesia and many other countries
It stores domestics finished goods
It too stores import of finished tyres which come from SriLanka, which is an
outsourcing of company for small tyre
It also stores finished goods which are for export purpose
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B. Flow of material
Trader CEAT
Raw
material
Bhandup Bhiwandi
(Warehouse)
(Warehouse)
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Panvel (Warehouse)
Bhandup Bhiwandi
(Warehouse) (Warehouse
)
Bhandup Nashik
Plant Plant
Possession of Imported raw material are first taken place at the Panvel warehouse,
from there it supplies to Bhandup warehouse as well as Bhiwandi warehouse. Nashik
plant gets the imported raw material from Bhiwandi warehouse. Whereas, Bhandup
plant gets the imported raw material from Bhandup warehouse as well as Bhiwandi
warehouse.
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Management of Business Logistic
Panvel
(Warehouse
)
Domestic Interport
Outsourcing:
Meaning:
In highly competitive markets, logistics outsourcing provides the operational
flexibilities to meet the changing needs of the customers. The critical reasons why
companies outsource are
To focus on core competencies
Resources constraints
Cost saving resulting from better management of the supply chain
Wide geographical coverage
JK Tyre has an outsourcing for the small tyres which is from Srilanka. Imports of
finished tyre are received in Panvel warehouse. From here it directly supply to
domestic customer and also to the foreign customer.
Interport: It means import the goods from one country and make some change or
not in the product within nearby port and directly export to other country.
For flow of Finished Tyres for Export purpose through warehouse
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Finished Tyre
Export
Panvel
(Warehouse
)
Divisional
England Distribution Centre
108
Exports
Ultoura Brand
C and F Markets
In Metro Brand
Agent
Customer
Finished tyres which are manufactured by the company for export purpose are stored
in Panvel warehouse. From there it goes to Divisional Distribution Center and then
goes to C&F agent (Clearing and Forwarding) after it is forwarded to the dealer and
then finally it reaches to the customer.
But, the company job is end to C&F agent. From C&F Agent Company gets the Bill
of payment.
In England JK Tyre sells with the name of ULTOURA BRAND and IN METRO
BRAND whereas, in USA it sells with the name of PIERLY BRAND.
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Management of Business Logistic
Introduction
Material handling has emerged as a new and complex science evolving rapidly. For
moving the material in and out of warehouse, various kinds of equipment and systems
are used depending on the type of products and volume to be handled. These
equipments are used for the movement of goods over a short distance for the purpose
of loading and unloading operations. Material handling in warehouse is restricted to
unitized form, which requires smaller size equipment. However, for bulk handling
material at logistics nodes, such as shipyards, ports and airports, different types of
equipment are used. In warehouse, the material handling operation is performed at the
following stages:
Efficiency of the material handling equipment adds to the performance level of the
warehouse. The internal movement of goods has a direct bearing on the order picking
and fulfillment cycle. The ware house is considered as a more labour intensive, if the
material handing equipments are more sensitive to labour productivity than the
manufacturing. There is much scope to reduce the labour and enhance the productivity
by using the emerging technologies in material handling. A good material handling
system will definitely enhance the speed.
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Management of Business Logistic
All this equipment used by company for the purpose of efficient flow of raw material
as well as finished tyre, it starts from the time of raw material unloaded till the time of
finished tyre loaded for distribution or delivery to customer.
◈ Machinery details
Machinery used for production process and which are available at
Bhandup plant:
6 mixers
2 scruders
1 cobelco
7 wire cutter
30 blades
72 truck tyre building
112 presses
350 tyre size
930 mould available
These are the machinery used for manufacturing of JK tyre
It does not mean that in a month company stop production process for 8 hour.
Machinery is repair one by one without stoppage of production process.
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Management of Business Logistic
◈ Distribution Management
Distribution channels helps in creating time and place utilities of the product, which
are important for customer satisfaction. The channel will help the firm to make the
product available at the right place and channel efficiency and effectiveness is greatly
dependent on the logistics operation of the firm to fulfill the demand. However,
logistics will help in the movement of the product to make it available in the right
quantity whenever the customer needs it. Hence the logistics network needs to be
integrated with the distribution channels of the company.
The distribution channel is the place of transaction for the firm’s product and it acts as
an interface between the customer and the firm. However, the effectiveness of this
interface is greatly dependent on the efficiency of the logistics operation to move
product in the required quantity and variety with speed.
In fact, The basic role of logistics in the distribution channels is to ensure smooth
movement of product to make them available at distribution outlets as and when they
are required by the customer. This is not an easy task, since it involves a great degree
of planning for material availability and movement at the lowest cost and with speed.
Domestic distribution:
JK Tyres DEALER
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Management of Business Logistic
J K tyre produces the finished tyre i.e. O.E.M. (Original Equipment Manufacture) and
are mostly supply directly to the dealer without storage except some dealer where
company stores the goods in O.E.M. Godown and dealer gets the finished tyre from
O.E.M. godown. In domestic distribution there are no intermediaries between the
company and dealer.
JK Tyre company job is till the dealer in domestic distribution. Company does not
supply the goods to user customer directly.
International Distribution:
JK Tyres
DEALER
CUSTOMER
Company supply export of finished tyre first to Divisional Distribution Centre, who
sent the goods to the Clearing and Forwarding Agent and they forward the good
through shipment and it reaches to the Dealers hand from their it goes to ultimate or
potential customer hand.
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Management of Business Logistic
Company job is till the C&F Agent, because the company gets the bill or payment
form C&F Agent.
Problems in distribution:
There are some problems faced by the company for providing the goods to the
customer on time or with minimum variance are
Transit time increasing in Rainy: In Rainy Season the transit time for
the distribution of goods increases. As usual it takes 5 to6 days for delivery
of goods but in rainy it increases up to 7 to8 days.
Forecast: Sometime Company forecast goes wrong and which make the
problem in the distribution strategy of a company.
Strike: Strike is very complicate situation for a company which affects the
production process of a company and which ultimately affects the
company distribution as well as customer need fulfillment.
For solving this problems company takes forecasting regularly and eliminate the
distribution problem to the lowest extent.
◈ Transportation System
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Management of Business Logistic
With limited choice of types of transportation and little difference in the prices and
quality of service offered by the suppliers of transportation some years back, transport
was considered as unimportant function. But today with a wide range of choice, the
scenario has changed and transport has become one of the very important deciding
factors in logistics.
In the movement of raw materials or products from place of production to the place of
consumption, transportation is the most important components of the logistical
system. It serves two purposes, one is product movement and the other is in-transit
product storage. Movement of the product can be achieved through various modes,
such as road, rail, air, and sea, subject to the availability of and access to the
infrastructure.
Road:
Road transportation is one of the promising means for agricultural and industrial
advancement of the country. It is suitable for short and medium distance where other
means are unable to reach. It provides door-to-door service, which is not possible with
other means. Road transportation provides the basic infrastructure to bring trade and
commerce from remote rural areas to the urban areas.
Road transportation helps assumed greater important due to the growing demand for
making the right product available at the place of consumption itself. Today road
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Management of Business Logistic
Railways:
Railways are the principal carriers of men and material and play a major role in
country’s trade and commerce activities. It is the main source of supplying essential
commodities, transporting them through length and breath of the country. Across the
world, railways have played an important role in industrialization and development of
the nation. It has been the primary means for movement of raw material and finished
goods.
Water:
This mode is the link between countries separated by water. Water transport is
classified into deep water transportation and navigable inland water transportation or
domestic water transportation on lakes, rivers or canals. Main advantage of water
transportation is its capacity to move extremely large shipment at a very low cost.
Air:
Compared to all other modes of transportation, air transport is less hazardous in
nature. Air transportation is a costly affair and it is used only for highly perishable
commodities and items, whose life is short and value is high.
CEAT Company use different mode of transportation for the domestic supply
of Goods which is different from that of international
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Management of Business Logistic
MODE OF
TRANSPORTATION
DOMESTIC INTERNATIONAL
Roadway Waterway
Airway
(Rare Cases)
For domestic:
In domestic movement of raw material and for finished goods company uses the Road
way, because of it daily Availability, Reliability and Cost Effective.
For international:
In international movement of raw material and for finished goods company uses the
waterway for transportation, because of it huge handling capacity and cheapest mode
of transportation in international trade. But company also use the Air transportation in
rare cases, this has been used when the customer required the goods urgently.
◈ Information system
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Management of Business Logistic
The degree of success of the decisions largely depends on the information quality and
timeliness. With the advancement in information and communication technologies,
the speed of information analysis and flow has increased tremendously. As a result,
efficiency and effectiveness of logistic operation have improved considerably, which
in turn has led to increasing the level of customer satisfaction.
There are some advantages of using the SAP information system in CEAT are
No duplication of work
Fast flow of internal information
Control tariff management
More efficient replenishment
More on time delivery
Avoiding the purchase of unnecessary equipment
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Management of Business Logistic
There is only one disadvantage which is that, it is too costly. Company has invested
Rs.10,00,00,000/- for the adopting the SAP Technology. But, company does not
consider it is a disadvantage, it can be consider as investment, because of using of
SAP technology the flow of information become faster and distribution of goods
made efficiently or with minimum variance.
Materials requirement planning (MRP) is a computer based system in which the given
master production schedule is exploded with Bills of Material, into the required
amount of raw materials, part and sub assemblies needed to produce the final products
in each time period of say a week or month (called as “Buckets”).
MRP is a scientific way of planning the material usage and ordering at various level
of production and monitoring the inventory stocks during these transactions.
MRP serves as key component for planning and controlling production operations and
procurement of materials and helps to control shop floor activities and vendor follow
ups.
The main aim of introducing such a package is to maintain a low level of inventory
without affecting the production schedules and ensuring timely deliveries.
1 – Sales Forecasting
2 – Master Production Schedule
3 – Bill of Material Explosion
4 – Gross Material Requirement
5 – Net Material Requirement
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Management of Business Logistic
Sales Forecasting: The output of this process is quantity demanded per year (or
per unit time) is known. This indirectly helps in knowing quantity to be supplied i.e.
manufactured to the market.
Demand Forecast
MRP Program
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Management of Business Logistic
Inventory Status
1st Step (Orders and Forecast): Company forecast the sales for future period
and also consider the new order comes from STU (States Transport Unit), from this
company gets the requirement of stock on monthly basis.
2nd Step (Demand Forecast): From the forecasting and order, the company gets
to know the actual demand of the product of a company in the market. They also do,
Demand forecasting for any additional quantities of raw material required, that
management decides to manufacture for smooth flow of the production process.
3rd Step (MRP Program): Company runs the MRP program, from where they
get the actual inventory requirement for future fulfillment of market demand. MRP
Program is run on regularly basis.
4th Step (Inventory Status): After running the MRP program, company gets the
exact inventory status or raw material available in hand.
5th Step (Net Material Requirement): Lastly, from the actual inventory
status, company gets the Net Material Requirement for the production of future tyre or
actual stock replenishment and accordingly they order for additional quantity which is
required.
Hence, in this way, how the company reduces the level of inventory and makes the
smooth flow of material in production process.
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Management of Business Logistic
JIT required close coordination of demand needs among logistics, carries, suppliers
and manufacturing. JIT also represents a tremendous opportunity for the logistics
function to contribute to the organization’s success by reducing inventory while
simultaneously maintaining or improving management/ Logistics Management.
It Reduces
Warehouse Charges
Material Handling Cost
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Management of Business Logistic
Advantages:-
Time Saving Process
Meet Working Capital Needs
Inventory Carrying Cost Reduce
Logistic cost
Logistics is the area where the firm has a lot of scope for cost control and reduction.
Logistics cost varies from 5 to35% of sales for different product-market. Hence the
management of logistics costs has become increasingly important due to its impact on
product profitability, product pricing, customer profitability and ultimately, corporate
profitability. Logistics can offer key source of competitive advantage through service
differentiation or by reducing costs and increasing corporate profitability. The firms
were increasingly focusing of planning and managing complex logistics operations
and networks, while reducing cost and enhancing service.
In a competitive market, firms require more accurate and detailed logistics cost
information form their cost accounting systems to work out the cost–benefits analysis
of their logistics strategies in order to design a cost-effective supply chain. Logistics
managers requires detailed information to determine how different products,
customers or supply channels affect the costs of providing logistics services. The
detail and complexity of the cost information will depend on the diversity of products
handled, customer requirements or supply channels used. The cost components that
are considered for computation of logistics cost.
Components of logistics costs
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Management of Business Logistic
Order processing
Order registration
Order checking and acceptance
Order processing
Co-ordination
Warehousing
Material handling
Material storage
Order picking & filling
Dispatching
Inventory
Inventory(WIP & FG)
Handling damages
Obsolesce
Shrinkages
Process
Non-chore activities
Faulty layout
Ergonomics
Set-ups
Packaging
Packaging stocks
Wastage
Transportation
Freight
Distribution
Transit damages
Service delays
The increased visibility of logistics costs will serve several purposes for the firm, such
as identification of direct costs, better understanding of price/volume relationships,
opportunity to address significant cost reduction measures, better evaluation and
justification of investment in new technology and give more attention to these costs.
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Management of Business Logistic
There are some measures for cost cutting which CEAT COMPANY applies
For reducing cost, Company sells the scrap to other company. Those company who
brought the scrap, goes for the manufacturing of a mud flap. They give name to mud
flap as GEAT.
This selling scrap minimizes the expenses and it also reduces the conversion cost.
For application of this the company does the regular forecasting for cost benefit.
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Management of Business Logistic
Therefore, it reduces the storage facility and also the material handling cost.
In CEAT supervisor have been motivated through the Key Result Area. Key Result
Area is work on the yearly basis. Company use these for the purpose of improve the
production of tyre and utilize the full production capacity. Key Result Area function
like
a) First the supervisor has given the target
b) It works in 10 point basis
In second column show their previous year target they have achieved.
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Management of Business Logistic
I. Step: Less the previous year target achieved with financial year
target given (200-250=50)
II. Step: Divide the extra target given i.e. 50 with 10 point i.e. 50/10=5,
then 5 is considering as 1 point for extra target achieved.
III. Step: Extra target achieved i.e. on an above 200 is divided by 5 i.e.
in case of A supervisor 230 target has achieved, in that 30 is the
extra target achieved then 30/5=6 point got by supervisor ‘A’
Hence, on the basis of the point the efficiency of the supervisor has found out.
It ultimately helps the company in reducing the wastage; improve the production
process which result into optimum utilization of production capacity and also it
increase efficiency of logistic function.
CHAPTER -5
RECOMMENDATION
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Management of Business Logistic
Employee Motivation
(Motivation at Plant Site)
Employee Supervisor
Motivation
No Motivation through Key
Factor result Area on
(Monetary & Ten Point
Non-Monetary Basis.
Benefit)
That’s why they never achieve their target of 250 metric ton (Day) and they
stick to 230
Conclusion: If Employee have given due waitage Just like supervisor it gives
more benefit to achieve their target.
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Management of Business Logistic
(For e.g.) In CEAT Mould Machine Takes 40 minutes for giving Final
Production
Conclusion: - It will increase the Production Efficiency and they will fulfill
their additional market demand.
CHAPTER -6
BIBLIOGRAPHY
Book Referred:
Logistic Management
-V.V.Sople
Logistic Management
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Management of Business Logistic
-David Boomberg
Notes Referred:
Elements of logistics Management
-Prof. Vikram Shrotri
Website Referred:
WWW.CEAT.COM
WEBILOGRAPHY
CONTACT WITH:
MR. HEMANT KARKARE Production Manager (Bhandup
Plant) of CEAT TYRE Limited
MR. RAHUL KAPARIA, Outbound Logistic Manager of
CEAT TYRE Limited
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