اثر تخطيط ومراقبة المخزون على ربحية الشركات الصناعية

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Published on April 27, 2014

Author: Nasser-Zaky

Source: slideshare.net

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اثر تخطيط ومراقبة المخزون على ربحية الشركات الصناعية فى ظروف عدم التأكد

Impact of Inventory Planning and Control on the Profitability of Industrial Companies in UncertaintyConditions “Application on Steel Industry Companies” Logistics Senoir Manager – Ezzsteel – Suez - Egypt E-mial: Nasserzaky@yahoo.com Tel: 00201006054604

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.............................................................................. ...................................................................... ....................................................................................... Purpose of Inventory........................................................ Type of Inventory............................................................ Nature of Demand............................................................. .................................................... 7.............................................................................. 7............................................................................ 7...................................................................... 8:............................................................................... 8................................................................................... 8.................................................................................................... 8...................................................................................................... 8Inventory Control............................................................................ 9.................................................. ................................................................................... Holding or Carrying Costs.................................................... 10................................................................................................................ 10Shortage Costs.............................................................................. 11PullPush............................ 11Push....................................................................................................... 11Pull.................................................................................................... 12...................................................................... 12Inventory Turn Over.................................................................... Stock-Outs............................................................................................ Service Level...................................................................................... Lead Time................................................................................................ Stcok Cover.................................................................................. :..............................

....................................................................... ................................................................ :............................................................................................... ....................................................................................................... ............................................. ................................................................................................. ....................................................................................... --- ...................................................................... ....................................... ................................... .................................. ................................................................... ............................................................ ............................................................................................................... ..........................................................................................................................

1/1 2/1 3/1HBI 4/1 5/1 6/1 7/1 2/2 3/2 4/2Suppply Chain Decesion Making Framwork 108

1/1 2/1

1 - Inventory Management

2 -– –

3 PullPush

4 - Liquidity Vs Profitability -A Case Study on Inventory Management of Cement Industry in Tamilnadu(1 ) Ashokkumar N. and Manohar Tamilnadu - - - - - ROI - - - Improving inventory performance with clustering based demand forecasts(2) Pradip Kumar Bala 1 Ashokkumar N. & Manohar V. (2010). Liquidity Vs Profitability -A Case Study on Inventory Management of Cement Industry in Tamilnadu. Advances in ManagementJournal, 3, 56-60 2 Pradip Kumar Bala, P. (2012). Improving inventory performance with clustering based demand forecasts. Journalof Modeling in Management 7 (1),23-37.

5 - - - - - - - - 3 Improving Inventory Management in Small Business: ( 1 ) Lining Bai and Ying Zhong - -ABC -A C - -ABC - - - 1 Bai, L. & Zhong, Y. (2008). Improving Inventory Management in Small Business: A Case Study. (Master’s thesis). Jonkoping International Business School.

6 Inventory Management as a Department for Improvemnet of Customer Service( 1 ) Musenga Francis Mpwanya Guating Province - - -Guating Province -Guating Province - - -Enterprise Resource PlanningERP ERP ERP Guating Province 5 On the relationship between inventory and financial performance in manufacturing companies( 1 ) 1 Mpwanya, M. (2005). Inventory management as a determinant for improvement of customer service. (Master’s thesis). University of Pretoria.

7 Vedran Capkun, Ari-Pekka Hameri, Lawrence A. Weiss -- - - - 6 1 Capkun, V., Hameri, A. & Weiss, L. (2009). On the relationship between inventory and financial performance in manufacturing companies. International Journal of Operations & Production Management, 29 (8), 789-806

8 INVENTORY MANAGEMENT INTRODUCING A FRAMEWORK TO ASSESS OPERATIONAL PERFORMANCE.(1 ) Author: Guido van Heck, BSc.Delft University of Technology Enterprise Resouurce PlanningERP -AB -A - - - - -BBSAP 1 Heck, G. (2009). Inventory management: introducing a framework to assess operational performance. (Master’s thesis). Delft University of Technology

9 -Fax ServerEDI - EDI -A SAPVila SAP -BB SAP - B

10 Determinants of successful vendor managed inventory Relationships in oligopoly industries. (1 ) Kim Dorling Coca Cola Amatil (NZ) Limited, Auckland, New Zealand, and John Scott and Eric Deakins University of Waikato, Hamilton, New Zealand vendor managed inventory (VMI) - VMI VMI NZ Food Industry ------- NZ Food Industry 1 Dorling, K. & Scott, J. Deakins, E. (2006). Determinants of successful vendor managed inventory relationships in oligopoly industries. International Journal of Physical Distribution & Logistics Management, 36 (3), 176-191

11 - - - Re-engineering materials management – A Case Study on Indian An Refinery( 1 ) Prasanto Kumar Dey - - - - - - - - - 1 Dey, P. (2001). Re-engineering materials management: A case study on an Indian refinery. Business Process Management Journal, 7 (5), 394-408.

12 - - - 9 Origins of profitability through JIT processes in the supply chain( 1 ) Jamshed J. Mistry Just In Time (JIT) . JIT 10 1 Mistry, J. (2005). Origins of profitability through JIT processes in the supply chain. Industrial Management & Data Systems, 105 (6), 752-768.

13 Process efficiency of the enterprise resource planningadoption( 1 ) Shaio Yan Huang, Shi-Ming Huang and Tung-Hsien Wu Department of Accounting and Information Technology, National Chung Cheng University, Chia-Yi, Taiwan, andWen-kai Lin Department of Accounting, Providence University, Taichung, Taiwan Enterprise Resource Planning (ERP) ERPTaiwan ERP ERP ERP Enterprise Resource Planning (ERP) ERP ERP ERP ERP . 1 Shaio Yan Huang, Shi-Ming Huang, Tung Hsien Wu, Wen-kai Lin, (2009). Process efficiency of the enterprise resource planning adoption. Industrial Management & Data Systems, 109 (8), 1085-1100.

14 - - - - - - -

15 - - -- - - -

16 - 1 2011 ---- , , ,, , , , ,, , , ,, , , ,, , , ,, , , , ,, , , , , ,, , , ESR 2011 FY Consolidated Financials ENEzzSteel - - - - - 1 PDF]ESR 2011 FY Consolidated Financials EN Ezz Steel-

17 - - Scrap (HBI) Hot Brquieted IronIron Ore BilletLong Steel Hot Rolled CoilHRC- (1)2010 1 Metal Buliten.4th steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes.

18 ScarpHBIIron OreBilletLong SteelHRC

19 ScarpHBIIron OreBilletLong SteelHRC --

20 ScarpHBIIron OreBilletLong SteelHRC

21 ScarpHBIIron OreBilletLong SteelHRC Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21st -22nd September2010 “Importance of Supply Chain Efficiency during Steel Market Changes. .

22 Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes 0 100 200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 2001200220032004200520062007200820092010 P r i c e $ Scarp HBI Iron Ore Billet Long Steel HRC 0 100 200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 1,400 2001200220032004200520062007200820092010 P r i c e $ Scarp

23 Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes 1Hor Brequited IronHBI Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes Iron Ore 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 2001200220032004200520062007200820092010 P r i c e $ HBI 0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00 900.00 1,000.00 1,100.00 1,200.00 1,300.00 1,400.00 2001200220032004200520062007200820092010 P r i c e $ Iron Ore HBI

24 Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes 0 100 200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 1,400 2001200220032004200520062007200820092010 P r i c e $ Billet 0 100 200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 2001200220032004200520062007200820092010 P r i c e $ Long Steel

25 Source Metal Buliten.4th Steel logistics Conference Belgium- Antwerp 21-22 September 2010, “Importance of Supply Chain Efficiency during Steel Market Changes Hot Rolled CoilsHRC - - 0 100 200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 1,400 2001200220032004200520062007200820092010 P r i c e $ HRC

26 - - - - - - --

27 - - - - -

28 - - - - - -

29 - - - - --

30    

31

32 PullPush

33 PullPush Inventory or Stock Concept

34 Inventory 1 Inventory is any idle resource held for future use 2 3 Inventory or Stock 4 5 1 2 2013 3 http://www.managementstudyguide.com/inventory-management.htm 4 www.syrcs.org/articles/marketing/ART-022.pdf 5 Sherif Hany Seif El Nasr, Bi-criteria Optimization To The Performance Of The Inventory Management System, Arab Academy For Sciences & Technology And Maritime transport, Institute of International Logistics, page 7.

35 Sherif Hany Seif El Nasr,Bi-criteria Optimization To The Performance Of The Inventory Management System Research, op. cit. p: 7. -– –

36 1 – 1 --

37 1 - - 1 -

38 - 1 - - - - - - - - - - - - - 1 www.pmpyd.org.sa/pub/ %20 -%20 .doc

39 1 2 -– 3 1 http://edara-eg.net/new_page_14.htm 2 2013 3 -

40 -Responsive -Efficiency - 1 1 -

41 - - - Just in Time - - - - - -- 1 1

42 Obsolescence Deterioration Pilferage / spoilage Price Changes

43 Purpose of Inventory1 –Periodical /Active inventory Safety Inventory - In -transit Inventory - Seasonal Inventory - 1 Kent N. Grourdin,Global Logistics Management, Blackwell Publishers Ltd, UK/USA, 2001, p: 61-62. 022.pdf-www.syrcs.org/articles/marketing/ART

44 Speculative Inventory - Dead Inventory - Type of Inventory 1 -Raw Materials -In Process Inventory -Subassemblies and Components 1 -

45 -Maintenance, Repair and Operating Supplies (MRO) -Packing Materials -Finished products -By- Products& Used items Nature of Demand1 -Independent demand -Dependent demand 1 1 -

46 criteria Optimization To The Performance Of The Inventory-BiHany Seif El Nasr,Sherif it, p: 21.c., opManagement System 1 Sherif Hany Seif El Nasr, Bi-criteria Optimization to the Performance of the Inventory Management System, op. cit, p: 21.

47 Supply Chain Decesion Making Framwork

48 Supply Chain Decesion Making Framwork Planning &,Supply Chain Management StrategySunil Chopra & Peter Meindl, 48.-, Library of Congress Cataloging, US, 2007, p: 46Third Edition–Operation 71 7 7 1 Sunil Chopra & Peter Meindl, Supply Chain Management Strategy, Planning & Operation – Third Edition,op. cit., p: 24-32.

49 8:1 8 Inventory Management Warehousing Management 8 - - - - - 2 1 - 2 -

50 8 8Inventory Control1 92 1 - 2 -

51

52 1 Holding or Carrying Costs –Cost of Capital Cost of storage facilities - Cost of spoilage/obsolescence 1 --

53 Cost of taxes and insurance - Cost of Handling1 - 2 1 Sherif Hany Seif El Nasr, Bi-criteria Optimization To The Performance Of The Inventory Management System, op. cit., p: 21. 2 www.syrcs.org/articles/marketing/ART-022.pdf, Op. Cit.

54 101 -Buyer Time -Transportation Costs -Receiving Costs -Other Costs 1 Sherif Hany Seif El Nasr, Bi-criteria Optimization to the Performance of the Inventory Management System, op. cit., p: 23-24.

55 10Shortage Costs1 2 11PullPush3 1 Sherif Hany Seif El Nasr, Bi-criteria Optimization To The Performance Of The Inventory Management System, Op. Cit., p . 2 www.syrcs.org/articles/marketing/ART-022.pdf, Op. Cit. 3 – 2004-

56 11Push - Made-to -stock Manufacturing Resource Planning (MRPII)     

57 11-Pull Made –to –order Lean Manufacturing Just –In –Time (JIT)  Just –In –Time (JIT) Pull  Pull Push Pull.   Push PushPull

58 121 12Inventory Turn Over 2 3 -------------- Stock-Outs Service Level -------------- 1 Sherif Hany Seif El Nasr, Bi-criteria Optimization To The Performance Of The Inventory Management System, Op. Cit., p . 2 2013 3

59 Lead Time Stcok Cover : Capital Cost

60 1 ABC Analysis2 Wilfreno Pareton -- -A -–- -B --–- 1 Kent N. Grourdin,Global Logistics Management, Op. Cit, p.72. 2 --

61 -C - - MRPMaterial Requirments Planning DRPDistribution Resource Planning

62 1 Dell 2 1 - 2

63 3 3 3

64 : 1 (Blaste Furnace) (Oxygen Furnace) (Electric Arc Furnace) Long Steel Flat Steel 1 Nasser Mohamed Zaky, Logistics Management and Cost Reduction inSteel Plants, Arab Academy For Sciences & Technology And Maritime Transport, Institute of International Logistics, Egypt, April 2010, p.5-7. 1

65 Source: Nasser Mohamed Zaky, Logistics Management and Cost Reduction inSteel Plants,op. cit. p.6.

66 -

67 -

68 - - - -

69 - - - - - - ERP - - -

70 Material Requirments Planning (MRP)Manufacturing Resouce Planning (MRPII) Enterprise Resouce Planning (ERP)

71 - SAB Lead Time Handling Equipment

72 5S Oracle First In First Out (FIFO) -1 Material Requirment Planning(MRP) 1 -

73 -Manufcturing Resource Planning (MRPII) MRP -Enterprise Resource Panning (ERP) MRPII Value Chain –

74

75 k

76

77

78

79

80 0000

81

82 Claim Form # Issue Date: 01/06/2005 Rev. # :01 Rev. Date : 02/10/2005 Date: To: Material Name: Supplier: Received Date: Quantity: Order # : Bill Of Lading # : Description: Required Action: Recommended compensation: Attachments: Dept. Manager Plant Manager Name: Name: Sign: Sign: CC:

83 Claims Status Report as of DD-MM-YYYY Claim # Material P. O. # Supplier Date Unit Qty. Claim Description Recommended Compensation Status Received Compensation Remarks Total Rec. Date Rem. Invoice #

84 Dinamic Updates o A,B,C Analysis o In-Transit Inventory o Information Flow Velocity

85 o Management Commitment o -

86

87 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10

88 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10

89

90 334,153,950259,283,41774,870,53322% 334,153,950229,930,574104,223,37631% 334,153,950245,004,51589,149,43527% 2011 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11

91

92 - - - - -

93 - - - - - -

94 - - -

95 - - - - - - -

96 - - -- -2013 -2013 -– 2004 -www.syrcs.org/articles/marketing/ART-022.pdf, -www.pmpyd.org.sa/pub/20%%20-.doc -eg.net/new_page_14.htm-http://edara

97 1- Ashokkumar N. & Manohar V. (2010). Liquidity Vs Profitability -A Case Study on Inventory Management of Cement Industry in Tamilnadu. Advances in Management Journal, 3, 56-60. 2- ESR 2011 FY Consolidated Financials EN Ezz Steel- 3- Guido van Heck, BSc. ( 2009).Inventory Management Introducing A Framework to Asses Opertaional Performance . (Master Thesis). Delft University of Technology 4- http://www.managementstudyguide.com/inventory-management.htm 5- http://www.worldsteel.org/pictures/programfiles/Fact%20sheet_Raw%20m aterials.pdf 6- Jamshed J. Mistry, (2005),"Origins of profitability through JIT processes in the Supply Chain", Industrial Management & Data Systems, Vol. 105 Iss: 6 pp. 752 – 768 7- Kim Dorling, John Scott, Eric Deakins, E. (2006). Determinants of successful vendor managed inventory relationships in oligopoly industries. International Journal of Physical Distribution & Logistics Management, 36, 176-191. 8- Kent N. Grourdin,Global Logistics Management, Blackwell Publishers Ltd, UK/USA, 2001. 9- Lining Bai and Ying Zhong.(2008).Improving Inventory Management in Small Business: A Case Study. (Master’s thesis). Jonkoping International Business School.Jonkoping UNIVERSITY. 10- Musenga Francis Mpwanya,. (July 2005). Inventory management as a determinant for improvement of customer service. (Master of commerce).Faculty of Economic and Management Science at the University of Pretoria

98 11- Nasser Mohamed Zaky,Logistics Management and Cost Reduction inSteel Plants, Arab Academy For Sciences & Technology And Maritime Transport, Institute of International Logistics, Egypt, April 2010. 12- Pradip Kumar Bala. (2012). Improving inventory performance with clustering based demand forecasts. Journal of Modeling in Management, Vol. 7 Iss: 1 pp. 23 – 37. 13- Prasanta Kumar Dey, (2001),"Re-engineering materials management: A case study on an Indian refinery", Business Process Management Journal, Vol. 7 Iss: 5 pp. 394 – 408 14- Shaio Yan Huang, Shi-Ming Huang, Tung-Hsien Wu, Wen-kai Lin, (2009),"Process efficiency of the enterprise resource planning adoption", Industrial Management & Data Systems, Vol. 109 Iss: 8 pp. 1085 – 1100 15- Sherif Hany Seif El Nasr,Bi-criteria Optimization To The Performance Of The Inventory Management System, Arab Academy For Sciences & Technology And Maritime transport, Institute of International Logistics, unpublished Research. 16- Sunil Chopra & Peter Meindl, Supply Chain Management Strategy, Planning & Operation – Third Edition,Library of Congress Cataloging, US, 2007. 17- Vedran Capkun, Ari-Pekka Hameri, Lawrence A. Weiss, (2009),"On the relationship between inventory and financial performance in manufacturing companies", International Journal of Operations & Production Management, Vol. 29 Iss: 8 pp. 789 – 806, Published in Business Process Management Journal. 18- 4th steel logistics Conference Belgium- Antwerp 21-22 September 2010 , “ Importance Of Supply Chain Efficiency During Steel Market Changes www.metalbulletin.com/events.

99 .

100 - - - - - - - - - - - -

101 - - - - - - - - MRP-MRPIIERP - - -

102

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