Fikremariam Teferi
Fikremariam Teferi
BY
Fikremariam Teferi
June, 2015
Dessie , Ethiopia
Wollo University
Graduate Studies
This is to certify that the thesis prepared by Fikremariam Teferi entitled “A case study of Dessie
city construction and housing development office in Amahara national regional state” and
submitted in fulfillment of the requirements for the Degree of Master of Arts in MBA (Master of
Business Administration) complies with the regulations of the University and meets the accepted
standards with respect to originality and quality.
Signature _____________
Wollo University
Dessie
(MBA).
________________________ ________________________
Prof. Sandeep Kumar (PhD.) Yiemre Ayalew (MBA.)
(Advisor) (Co-Advisor)
ACKNOWLEDGEMENTS
First and for most I would like to express my deepest gratitude to my advisors Prof. Sandeep
Kumar and Ato Yimer Ayalew for their invaluable and constructive comments, suggestions and
feedback throughout the paper. Without their constructive comments and suggestions, this study
would not have been successful. I am very much indebted to the kindness, patience, and warm-
welcome they have shown me in the course of time.
I would like to take this opportunity to thank my colleagues and Ato Alayu Yirga without their
encouragement and support this research could not have been made possible. I would also like to
extend my thanks to the Dessie City Construction and Housing Development Office employees
who participated in this study.
Lastly, I own a special debt to my brothers, sisters, and all best friends for their unconditional
love, moral, financial and material support all through the years; if it were not their unlimited
support and encouragement, I wouldn’t have succeeded.
i
Table of Contents
Contents Page
Acknowledgment---------------------------------------------------------------------------------i
Table of Contents------------------------------------------------------------------------------- ii
List of Figure--------------------------------------------------------------------------------------v
List of Acronyms------------------------------------------------------------------------------------------------vii
Abstract ------------------------------------------------------------------------------------------viii
CHAPTER ONE...........................................................................................................1
1. INTRODUCTION.....................................................................................................1
CHAPTER TWO..........................................................................................................9
2. REVIEW OF RELATED LITERATURE..............................................................9
CHAPTER THREE......................................................................................................33
3. RESEARCH METHODOLOGY............................................................................33
CHAPTER FOUR.........................................................................................................36
iii
4. PRESENTATION, ANALYSIS AND DISCUSSION OF DATA.........................36
CHAPTER FIVE..........................................................................................................50
5. SUMMARY, CONCLUSION AND RECOMMENDATION..............................50
5.1 Summary..............................................................................................................50
5.2 Conclusion...........................................................................................................52
5.3. Recommendation..............................................................................................53
References
Appendix –A Questionnair
Appendix –B Interview questions
Appendix –C Important Documents used in inventory management system of the branch
office
iv
List of Figures
Figure Page
v
List of Tables
Table Page
vi
List of Abbreviations/Acronyms
IM Inventory management
JIC: Just-in-case
JIT: Just-in-time
vii
ABSTRACT
This study attempted to assess the inventory management practice of Dessie Housing and
Development Agency branch office. The type of research design was descriptive survey. The
study employed both quantitative and qualitative methods (mixed method). The total number of
the target population was 54 among which 18 participants were selected using purposive
sampling. Two employees of the office were also purposively selected for an interview (Branch
manager and logistic manager). The data were collected through questionnaire, interview and
document analysis. The quantitative data were collected through self rated questionnaire where
the items are rated using Likert Scale ranging from 1= strongly disagree to 5=strongly agree.
The items are 49 in number, which are categorized into seven groups. Seven generalized
questions were designed for the interview. Necessary documents that are essential to carry out
inventory management were examined to perform the document analysis. The quantitative data
was analyzed using mean scores and standard deviations by categorizing the mean scores into
intervals. The qualitative data collected through interview and document analysis were analyzed
in word and paraphrased. The major findings of the study are : concerning inventory controlling
mechanisms materials are released from storerooms only on the basis of requisitions which are
approved by a responsible official of the department, strategies being followed by the branch office in
overcoming the problems of inventory are Standard price method, Weighted average cost method and
First in first out method. Among the C onstrains the main ones are a storage problem in its stock and
significant losses of construction materials. To generate inventory record reports the organization
conducts regular auditing inventory records and perpetual inventory records are updated
promptly. Finally, further research is recommended to investigate more the practice of inventory
management controlling system in the study area..
1. INTRODUCTION
1
In the JER approach, all resources minimized, including inventory, workers, equipment, job
classifications, and product parts and subassemblies (Martin et al, 1992).
Meanwhile, U.S. managers use an entirely different concept that some authors have referred to as
just-in-case (JIC). In the JIC approach to resource management, large amounts of slack resources
kept on hand to guard against contingencies such as late deliveries, poor quality, production
bottlenecks and fluctuations in demand. Of course, these concepts have some very important
implications for the resources themselves. JER and JIT require highly skilled and highly
dedicated cross trained workers, as well as high quality raw materials and well maintained
equipment. In the JIC environment, high skill levels and high quality materials and equipment
are not as critical. For example, in the area of inventory and production lot sizes, the idea,
according to the applicable sub-concept of optimization, is to find the economic order quantity or
batch size (EOQ) that will minimize the conflicting costs involved in the decision, (e.g., ordering
and carrying costs or setup and carrying costs) (Martin et al, 1992).
Industrial surveys conducted in developing countries have shown that proper IM has a significant
role to play in promoting industrial development (Goonatilake, 1990). Economists have long
puzzled over astounding differences in productivity across both firms and countries. For
example, growth domestic product per capita in the US is about ten times that of India. A natural
explanation for these productivity differences lies in variations in management practices. In a
large project measuring management practices across firms and countries, finding large gaps in
management practices between developing countries and the US and Europe. A project funded
by International Growth Centre (IGC) to evaluate the impact on firm performance undertook a
management experiment in India with 20 textile firms of about 300 employees. The experiment
collected detailed performance metrics on aspects such as output, inventory and quality at the
firms to understand the productivity benefits of improved management. The evidence suggests
that Indian factories are typically disorganized, with inventories and spare parts chaotically
organized, inadequate performance tracking, and extremely poor quality control. The evidence
on management practices presented above suggests similar issues will arise in other developing
countries. In particular, the suspicion is that Indian firms are likely to be better managed than
most African firms (Bloom and Reenen, 2009).
2
Inventory management is concerned with keeping enough products on hand to avoid running out
while, at the same time maintaining a small enough to inventory balance to allow for a
reasonable return on investment. Proper inventory management is important to the financial
health of the organization. The overall efficiency of IM is extremely important for two reasons.
First it represents a significant segment of total assets for most business firm. Second they are
least liquid of current asset and thus errors in inventory management are not quickly remedied.
As a result, a business must control its material from the time they are ordered until the time they
are shipped to customers. No cost accounting system can effective without proper and efficient
control of inventory. This is also because, quite often inventory is the largest single element of
cost and as such an efficient system of inventory control leads to a significant economy in the
total cost (Arora, 2003).
When a firm holds goods for future sale, it exposes itself to a number of risks and cost. The
effective management of inventory involves a tradeoff between having too little and too much
inventory that is optimum level of inventory. In achieving this trade off, the financial manager
should realize that risk and costs may be closely related. Some cost such as purchase price of
goods, involve little risk and may be calculated in advance with some accuracy. Other costs, such
as damage to goods in warehouse, are incurred only when a risk materials (Ibid, 2003).
When firm’s holds goods, they expose themselves to the possibility that the goods will not be
sellable this is due to current market factors deriving from change in styles, tastes, or other
factors. When the product is no longer wanted, the firm must sale it at a fraction of its value or
destroys it. The spoilage of goods also occur when a product is not sellable because of
deterioration during storage such as foods that rot plant that die ,garments that are attacked by
month, candies that discolor or chemical that decompose. (John & Hampton, 1989)
on all economic activities. It contributes to the national output and stimulates the growth of other
sectors through a complex system of linkages.
3
It is noted that about one-tenth of the global economy is dedicated to constructing and operating
homes and offices (UNEP, 1996).
Construction work in developing countries overwhelmingly involves simple physical labor. This
is the case in Ethiopia too. In 2005, only 7.19 percent of the employees are skilled. In terms of
female -male, lab our ratio, about 85 percent of the work force in the construction industry were
males, while the balance were female employees in 1999. Since Ethiopia is a country in
transition from public sector dominance to private sector, the share of public sector in the
economy has been significant in the construction industry, though gradually declining (Ethiopian
Economics Association Report, 2007).
To overcome the above problem effectively a firm should use a system approach to inventory
management. A system approach considers in a single model all the factors that affect the
inventory. As the goal of effective inventory management is to minimize the total cost – direct
and indirect that associated is on item considered important. If a firm can run out of an item
without losing a sale or disappointing a customer, it may waste money in keeping a close watch
on the item .Therefore, a careful consideration in inventory management should be given to the
following items. (1) High cost items, these items must be closely managed to prevent theft,
breakage or other loss, because the loss of single item can be costly. (2) High volume of sales, it
should be managed carefully (management of Amahara National Regional State Construction
and Housing Development Agency Dessie City Branch Office).
These conditions there by, adversely affect the profit and operation of the organization. This is a
very important issues to pay attention because exclusive investment in inventories result in an
illiquid corporations one that must continually borrow in order to have enough cash on hand
because of cost of capital tied up in inventories (Bhall, 2003).
4
In construction project, the tracking and locating of materials at the construction jobsites are the
most important problems related to construction materials and inventory management (Song,
2005; Navon & Berkovich, 2006; Nasir, 2008). Materials’ tracking and locating is important to
ensure that materials are available at the right time, in the right place (Song, 2005), and at the
quantity required. Issues regarding the tracking and locating of materials on-site have received a
great concern in construction industry as materials always come in bulk without proper
identification. The improper or inadequate management during the materials receiving process,
together with the traditional materials tracking has made it difficult to track materials location in
construction jobsite when the time they are needed.
Inventory management in construction project could be affected by several factors such as;
inadequate storage space (Sardroud, 2012), over ordering and double handling (Donyavi &
Flanagan, 2009); and incomplete and lack of up-to-date information regarding on-site stock
(Navon & Berkovich, 2006). The lack and incomplete of up-to-date information regarding on-
site stock is caused by the poor tracking and locating of materials in construction sites. Thus,
there is a need for a proper IM in order for the materials to be tracked and located easily; and
without employing additional costs.
6
What inventory controlling mechanisms does the agency use?
What are the strategies being followed by the agency in overcoming the problems of
inventory?
What constrains or a bottleneck does inventory management system face in the day to
day organizational activities?
What are the systems the agency uses to record, store retrieve and generate reports of
inventory?
To explore the strategies being followed by the agency in overcoming the problems of
inventory.
To find out the constraints of the organization faces in inventory management of its day
to day organizational activities.
Identify the systems used by the organization to record, store, retrieve and generate
reports of inventory.
7
particularly investigated only the material management aspect of the construction company.
8
CHAPTER TWO
Inventory control means availability of materials whenever and wherever required by stocking
adequate number and kind of stocks. The sum total of those related activities essential for the
procurement, storage, sales, disposal or use of material can be referred to as inventory
management. Inventory managers have to stock-up when required and utilize available storage
space resourcefully, so that available storage space is not exceeded. Maintaining accountability
of inventory assets is there responsibility. They have to meet the set budget and decide upon
what to order, how to order and when to order so that stock is available on time and at the
optimum cost (Benedict and Margeridis, 1999). Hence, Inventory management involves planning
organizing and controlling the flow of materials from their initial purchase unit through internal
operations to the service point through distribution (Smaros, et al., 2003).
Inventories constitute one of the largest and most tangible investments of any retailer or
manufacturing organization. Intelligent inventory management strategies can not only help boost
profit but they can mean the difference between a business thriving or barely surviving. Holding
inventories at the lowest possible cost and giving the objectives to ensure uninterrupted supplies
for on-going operations is the aim of inventory management. When making decisions on
inventory, management has to find a compromise between the different cost component, such as
the cost of supplying inventory, inventory holding cost and cost resulting from sufficient
inventories (Peterson & Silver, 1998; Zipkin, 2000). According to Miller (2010), inventory
control is the activity which organizes the availability of item to the customers.
9
It coordinates the purchasing, manufacturing and distribution functions to meet the marketing
needs.
This role include the supply of current building material items, new buildings, consumables,
obsolescent items and all other supplies. Inventory enables a company to support the customer’s
services, logistics or building activities in situation where purchasing or manufacturing of the
items is not able to satisfy the demand. Inventory plays a negligible row in the growth and
survival of an organization in the sense that failure to an effective and efficient management of
inventory, will mean that the organization will lose building customers and quality will decline.
In other to attain its organizational objectives, a business is to meet customer’s needs. Customer
desire has always been a vital issue in a company to increase it (Tersine, 1994; Potilen &
Goldsby, 2003). Kotler (2002), posits that inventory management refers to all the activities
involved in developing and managing the inventory levels of raw materials, semi-finished
materials (working-progress) and finished good so that adequate supplies are available and the
costs of over or under stocks are low.
Inventory management is primarily about specifying the size and placement of stocked goods.
Inventory management is required at different locations within a facility or within multiple
locations of a supply network to protect the regular and planned course of production against the
random disturbance of running out of materials or goods. The scope of inventory management
also concerns the fine lines between replenishment lead time, carrying costs of inventory, asset
management, inventory forecasting, inventory valuation, inventory visibility, future inventory
price forecasting, physical inventory, available physical space for inventory, quality
management, replenishment, returns and defective goods and demand forecasting. Balancing
these competing requirements leads to optimal inventory levels, which is an on-going process as
the business needs shift and react to the wider environment (Ghosh & Kumar, 2003).
Rosenblatt (1977) says: “The cost of maintaining inventory is included in the final price paid by
the customer. Good in inventory represent a cost to their owner; the manufacturer has the
expense of materials and lab our. The wholesaler also has funds tied up therefore; the basic goal
of the manufacturers is to maintain a level of inventory that will provide optimum stock at lowest
cost. Morris (1995) stressed that inventory management in its broadest perspective is to keep the
most economical amount of one kind of asset in order to facilitate an increase in the total value
of all assets of the organization human and material resources.
10
Ogbo (2011) posits that the major objective of inventory management and control is to inform
managers how much of a good to re-order, when to reorder the good, how frequently orders
should be placed and what the appropriate safety stock, is for minimizing stock-outs. Thus, the
overall goal on inventory is to have what is needed, and to minimize the number of times one is
out of stock.
Ghosh & Kumar (2003) defined inventory as a stock of goods that is maintained by a business in
anticipation of some future demand. This definition was also supported by Brag (2005) who
stressed that inventory management has an impact on all business functions, particularly
operations, marketing, accounting, and finance. He established that there are three motives for
holding inventories, which are transaction, precautionary and speculative motives. The
transaction motive occurs when there is a need to hold stock to meet production and sales
requirements. A firm might also decide to hold additional amount of stock to cover the
possibility that it may have under estimated its future production and sales requirements. This
represents a precautionary motive, which applies only when future demand is uncertain. The
speculative motive for holding inventory might entice a firm to purchase a larger quantity of
materials than normal in anticipation of making abnormal profits. Advance purchase of raw
materials in inflationary times is one form of speculative.
Bailey & Farmer (1982) define inventory as the goods purchased from sources out of the
organization that are used to produce finished products. Stukhart (1995) defines inventory as the
items that are used to produce a product and which include raw materials, parts, supplies and
equipment items. Stukhart (1995) defines IM as the activities involved to plan, control, purchase,
expedite, transport, store, and issue in order to achieve an efficient flow of materials and that the
required materials are bought in the required quantities, at the required time, with the required
quality and at an acceptable price. Plemmons & Bell (1995) define IM as the plan and control of
all activities to ensure the correct quality and quantity of materials and equipment to be installed
as specified in timely manner, obtained at reasonable cost and are available when needed.
Dobler & Burt (1996) state that IM is designed to improve the activities related to the flow of
materials. They add that inventory management should coordinate purchasing, inventory control,
receiving, warehousing, materials handling, planning, and transportation. As it is described
above, different researchers provide different definitions for inventory management. In the
context of the construction industry inventory management is concerned with the planning,
11
identification, procuring, storage, materials handling, receiving, transportation and distribution of
materials.
The first consideration is the overall objective of the work of stock control. Like all other
activities in the company, IM has to contribute to the welfare of the whole organization. The
logistic operation must aim to 'contribute to profit by servicing the marketing and financial needs
of the company. The aim is not to make all items available at all times as this may well be
detrimental to the finances of the company. The normal role for stock control is to 'meet the
required demand at a minimum cost. 'The aim of long term profitability has to be translated into
operational and financial targets which can be applied to daily operations. The purpose of the
inventory control function in supporting business activities is to optimize three targets: Customer
service, Inventory costs .Operating costs Tony Wild (1997:6).
According to Tony Wild targets, the first target, customer service, can be considered in several
ways, depending on the type of martial demand. In a general stores environment the service will
normally be taken as 'availability ex stock', whereas in a supply to martial specification, the
service expected would be delivery on time against customer requested date. The second target,
inventory costs, requires a minimum of cash tied up in stock. This target has to be considered
carefully, since there is often the feeling that having any stock in stores for a few months is bad
practice. In reality, minimizing the stock usually means attending to the major costs; very low
value items are not considered a significant problem. Low inventory can also be considered in
terms of space or other critical resources. Where the item is voluminous or the stores space
restricted, the size of the items will also be a major consideration. The third target, avoiding
operating costs, has become more of an issue as focus has been placed on stock management.
The prime operating costs are the stores operations, stock control, purchasing and associated
services. The development of logistics, linking distribution costs with inventory, has added a new
set of transportation costs to the analysis.
12
Optimizing the balance between these three objectives is the focus of stock control.
1. No under stocking: - Under stoking leads inevitable to materials running out of stock at
the same time or the other. Shortage of materials may arise at a time when they are
urgently needed. The delay or stoppage in production due to non availability of materials
is very costly and result in loss of profit.
2. No over stocking: - Inventory in materials must be kept as low as possible considering
the production requirement and financial resources of the business. Over stocking locks up
capital and causes high storage cost there by results adverse affect on profit.
3. Economy in purchasing: - By purchasing materials at the most favorable prices the
purchases is able to make available contribution to reduction in cost.
4. Minimum wastage: - In order to minimize loss of materials proper storage condition
should be provided to different types of inventory. Loss of materials occurs due to
deteriorations, obsolescence, theft, broken etc. all round efforts should be made to keep
these losses at the minimum.
5. Proper quality: - While purchasing materials, due consideration should be given to the quality.
It is no use purchasing material of inferior quality or very superior quality or very superior
quality. In business and construction activities, generally quality is first defined in terms of
relationship to need or function. That is the suitability of the items in satisfying the particular
need at hand.
Some function of agency, such as purchase of raw materials, physical dependency. Maintenance
of inventories allows the agency to decouple these functions so that each can be planned,
customers with selection choices and decouples the purchasing function from materials function.
Organization invests a substantial portion of its capital in inventory and stocks inventory as
optimal level to perform its operation on continuous basis. Economists have establish three
motives for holding inventories, however, depending on the nature of business and objective they
try to achieve there is also a contractual reason for holding inventories. Bhalla (2000:353) wrote
about motives of holding inventory the following.
1. Transaction motives for holding inventory: - Is to satisfy the expected level of activities
of the firm.
2. Precautionary motives for holding inventory:-Is to provide a cushion in case the actual
level of activity is different than anticipated. If demand exceed expectations (either in
total or for a particular ingredient sales will probably either be lost or if made less
profitable.
3. The speculative motive for holding inventory: - Might entice a firm to purchase a large
quantity of materials than normal anticipation of making abnormal profits. Advance purchase of
raw materials in inflationary times is one form of speculative behavior. A second reason for
speculative inventory purchases may involve an anticipated change in a product. Occasionally
there may be necessary to carry a certain level of inventory to meet contractual agreement.
13
Bhalla (2000) described stock out costs incurred when ever a business is unable to fill orders
because the demand for an item is greater than the amount currently available in the inventory.
Inventory shortage may result in one or more of the following:
high costs commit and with ‘crash’ procurement,
less efficient and economic building schedules,
and customer dissatisfaction and loss of quality.
When a stock out in row materials occurs, for example, stock cost include the expense of placing
special orders (back ordering). The organization holds inventory of high level as depend on the
following factors as the Pitzman (2000:596) argues.
1. Customer service: - Creating inventory can speed delivery and improve to time delivery.
Inventory reduces the potential for stock outs, and back orders, which are key concern of
whole sellers and retailers. A back order is a customer ode that cannot be filled when
promised or demanded but filled late.
2. Ordering cost: - Each time organization places a new order, it incurs an ordering cost or the
cost of preparing a purchase orders for supplies. This ordering cost force put pressure for
high inventories.
3. Transportation cost: - Sometimes, out bound transportation cost can be reduced by increasing
inventory levels. Having inventory on hand allows more carload shipments and minimizes
the need to expedite shipments by more expensive mode of transportation. Bhar (1991)
summarized the solution to the holding inventory to be hold by the agency. He advised the
quantity of inventory to be decided after taking the availability of finance, the quantity
discount allowed, the cost of storage and storage space available, order placing and receiving
costs, risk of loss due to falling prices, deteriorations. Obsolescence, theft, broken materials
etc, are taken into consideration.
14
2. Dynamic inventory problem: in dynamic inventory problems, the goods have value
beyond the initial period; they do not loss their value completely over time. Dynamic
inventory problem results a martial losses that affect a firms operation negatively.
Losses of materials may arise during handling storage or during process of manufacture such
losses or wastage is classified in to two categories: normal and abnormal losses. Normal losses
are losses which is necessary to be incurred and thus is on avoidable but, may be controlled to a
limited extent. Loss due to breaking the bulk, when materials are purchased in large quantity and
issued to production in small lots, some differences likely to normal loss categories, while
abnormal losses are theft or pilferage, breakage, fire accident, improper storage resulting in
deterioration of materials etc.
keeping in mind customer's expectations. The typical tasks associated with an inventory
management system are (Tersine & Campbell (1977), Ammer (1980), Stukhart (1995)).
15
Fig 2. 1. Typical Materials Management in Construction (Thabet, 2001).
Figure (2.1) depicts the different phases of the material management process including the
relationship and interdependency between the different activities in each phase. From this figure
it can be seen that decisions taken at each phase in the system, directly affect the activities of the
phases that follow (Thabet, 2001).
Arora (2003) further states an efficient system of materials control should be comprehensive
enough to cover purchase system, storage system, issue to production and determining stock
level for each item of materials.
This standard rate should be compared with actual turnover rate. If the actual turnover rate is less
than the standard, it implies that its actual rate of consumption is less than the stipulated rate and
the item is thus slow moving. Monthly or quarterly reports on such material should be prepared
for presentation of management. This report should show turnover rate, purchase and
consumption of these items is quantities as well as values. This will help in not only detecting
but also controlling slow and non moving items.
17
manager, the investment of funds in inventory is an important aspect of logistic management.
Consequently, the logistic manager must be familiar with why to control inventories effectively,
so that, capital may be allocated efficiently. And the other responsibilities of inventory Control
are Stores play a vital role in the operation of organization. Generally un worked material is
stored and the place where it is stored is called Store Room. It is in direct touch with the user
departments in its day-to d ay activities. The chief aim of the stores is to ensure the smooth flow
of production without any interruption. Stores generally include raw materials, work in progress
and finished goods. Effective storekeeping and inventory control are indispensable to the control
of material cost. Further, stores often equated directly with money, as capital is blocked in
inventories. (U.S. Small Business Administration Edited by SCORE 471).
Purpose of Storekeeping
(1) Storekeeping helps to examine carefully all goods and materials on receipts.
(2) It is essential to arrange for a systematic and efficient storing of materials.
(3) Storekeeping ensures accurate and prompt distribution of materials to user departments as per
issue requisition note.
(4) It is essential because stores often equated directly with money, as capital is blocked in
inventories.
Functions of the Storekeeper
The store is a service department headed by the storekeeper who holds the responsible position
in the organization of the stores department.
He is as much responsible for the articles in charge as a cashier for the cash .It functions are
(1) He must receive raw materials, components, tools, equipment and other items and account for
them properly.
(2) He must provide adequate and proper storage and preservation to the various items.
(3) He must check, and provide proper classification and codification of materials.
(4) Issue the materials as per material issue requisition duly signed by an authorized person.
(5) He has to take steps to prevent leakage, theft, wastage and deterioration.
'(6) He must ensure good storekeeping.
(7) He should not permit any person without authorization.
(8) He should maintain proper records in order to know desired quantities available.
(9) He must provide adequate in formations to the top executives for verifications and effective
decision making.
18
Stores Layout
In order to achieve the objectives of effective inventory control, well planned layout of stores
should be required. A planned stores layout will facilitate easy movement of materials, good
housekeeping, sufficient space for materials handling. It ensures effective utilization of storage
space and judicious use of storage equipments. The stores department should be equipped with
shelves, racks, pallets and proper preservation from rain, light and other such elements. An ideal
location of stores should facilitate the volume and variety of goods to be handled. In order to
bring down the transport cost it should be close to roads or railway stations. And also as far as
possible, the stores department should be near to the receiving department. In the case of large
organizations usually stores attached to each consuming department, whereas receiving is done
centrally.
Types of Stores
The types of stores depend on the size, types and policy of the organization. Organization of
stores varies from concern to concern. As per the requirement of the firm the stores organization
(a) Centralized Stores.
(b) Decentralized Stores.
(c) Combination of both, i.e., Centralized Stores with Sub Stores.
(a) Centralized Stores: This system is suitable to small-scale industries where it is desirable to
centralize the materials in one department. Under this system, the store room will be most
conveniently situated where it is near to all the departments.
(b) Decentralized Stores: Under this system each department has its own stores. It is suitable to
large concern where there are several departments each using a different type of material from its
own stores. In this system all the disadvantages of centralized stores can be eliminated.
(c) Combination of Both: This system is also termed as Imp rest System or stores’ control.
Centralized Stores with Sub Stores is usually adopted in large factories where departments are
situated at a distance from the central stores. In order to minimize the cost of transportation and
materials handling, this type of organization would be located nearer to the receiving department.
Under this system material receipts are stored in the central stores and issues are made to the
sub-stores. Under imp rest system of stores control sub stores which are located nearer to the
central stores for the purpose of draw supplies from central stores and issue the required quantity
to production. To maintain the stocks at the predetermined level, the sub-stores make requisition
from the central stores.
19
Fixation of Stock Level
Material control involves physical control of materials, preservation of stores, minimization of
Obsolescence and damages through timely disposal and efficient handling. Effective stock
control system should ensure the minimization of inventory carrying cost and materials holding
cost. Level of stock is the important aspect of inventory control. Stock level may be overstocking
or under stocking. Overstocking requires large capital with high cost of holding. In the case of
under stacking, production and overall performance of the concern as a whole will affect.
Thus, fixation of stock level is essential to maintain sufficient stock for the smooth flow of
production and sales. The greater the opportunity cost of funds invested in inventory, the lower
the optimal level of average inventory and the lower the optimal order quantity
Once this are assessed, the analysts then choose a basic approach either risk are addressed
separately, or the uncertainly approach, in which these faces are simultaneously. The certainty
approach is tractable, well tasted and easy to implement. However, because of the way it handles
risk the certainly approach is not applicable to static inventory problem. In certainty approach
risk is usually addressed though the use of safety stock. The uncertainty approach on the other
hand, is applicable in these static inventory problems, because this approach can also address
dynamic inventory problems, but simulation is required and the resulting methodology does not
lead to a definitive strategy (Bhalla, 2000).
The classical inventory model, which includes both simpler deterministic model and more
complex probabilistic models, it is assumed that demand is either uniform or dispersed and
independent or to fluctuate over time due to random elements.
20
These types of demand situation are common in retailing and some service operations.
In managing inventories, the firm’s objective should be in consonance with the share holder’s
wealth maximization principle. To achieve this, the firm should determine the optimal level of
inventory. Efficiently controlled inventories make the firm flexible. In efficient inventory control
result in unbalanced inventory and inflexibility, the firm may sometimes run out of stocks and
sometimes may pile up unnecessary stock. This increase the level of investment and makes the
firm un profitable.
To manage inventory efficiently, answer should be sough to the following two questions. How
much should be order? When should it be ordered?
Generally speaking, four types of inventory control system are in use (Pandy, 1999).
21
2.11.1 The cyclical or fixed order interval system
When most business was small and uncomplicated, this control system was used in all types of
operation manufacturing, service, whole sale, and retail. It is time based operation which
involves scheduled periodic review of the stock level of all inventory items, stock levels can be
monitored by physical inspection, by visual review of perpetual inventory cards, or by automatic
computer surveillance. In most operation perpetual record is maintained.
The first operating questions when to order is answered or controlled by the review dates
established by inventory manager. If material usage has remained reasonably stable, an order (or
release against order) is usually placed each time the item is reviews. The to be ordered generally
is to be determined by three factors the number of days between reviews, the anticipated daily
usage during the cycle period, and the quantity which is actually on hand and on order at the time
of the review. In this system a small safety stock is generally carried, based on the observed lead
time variability. Inventory levels and tightness of control thus determined by the establishment of
the cycle. High value A and B items typically are placed on short cycles and C items on longer
cycles.
In most inventories a small proportion of items accounts for a very substantial usage (in terms of
monetary value of annual consumption) and large proportion of items accounts for a very small
usage. ABC analysis advocates in essence a selective approach to inventory control which calls
for a greater concentration of on inventory items for the bulk of usage of value. ’A’ item
represents the most important items, generally consists of 10 to 15 percent of inventory items and
accounts for 60 to 75 percent of annual usage value, category ‘B’ representing items and
accounting for 20 to 30 percent of annual usage value. Category ‘C’ representing of lest
importance, generally, consist of 40to 60 percent of inventory items and accounts for 10 to 15
percent of annual usage value.
The following procedures may be used for determining the three categories.
22
Record the running cumulative totals of annual consumption value and express
them as percentage of the total value of consumption express each number in the
list, through, as percentage of n (these percentage are actual cumulative
percentage).
A strong a dependable relationship with supplies who are geographically not very
remote from transportation system.
A reliable transportation system
An easy physical access in the form of enough doors and conveniently located
docks and storage areas to dovetail in coming supplies to the needs of assembly
line.
23
Economic Order Quantity: EOQ is one of the important techniques used to determine the
optimum quantity or number of orders to be placed from the suppliers. The main objectives of
economic order quantity are to minimize the cost of ordering cost of carrying materials and total
cost of production. Ordering costs include cost of stationery, salaries of those engaged in
receiving and inspecting, general office and administrative expenses of purchase departments.
Carrying costs are incurred on stationery, salaries, rent, materials handling cost, interest on
capital, insurance cost, risk of obsolescence, deterioration and wastage of materials and . In
general economic order quantity model also can be useful to the logistic manager for planning
inventory financing (Banerjee, 1991). When demand or usage of inventory is uncertain, the
logistic manager may try to effect policies that will reduce the average lead time require
receiving inventory, once an order is placed. The logistic manage risk involved in caring
inventory. The major risk is that the market value of specific inventory will be less than the value
at which they were acquired certain types of inventories are subject to obsolescence, whit her it
be in technology or in customer tastes (Vanhorne, 1991).
The approach in determining the EOQ is based on the following assumptions (Karajewski &
Pitzman, 2000).
The forecast usage/ demand for a given period, usually one year is known.
The usage or remand is even through the period
Inventory orders can be replenished immediately (there is no delay in placing and
receiving orders.
The cost per order is contrast
The cost of caring is a fixed percentage of the average value of inventory
24
2.12 Components of Inventory Control System
Adequate records are must in any control system, but too many records can have a disastrous
effect. No one inventory control system will work in all plants. Each system must be developed
to fill specific requirement. Practically every system, however, make use of certain forms that
have proved to be essential to good inventory control. These include:
25
Visual review: a highly subjective method of determining when to recorder is
visual review of stock in inventory. For example in old time general store, the
owner would inspect his inventory and determine what should be reorder. This
techniques still has limited application where the cost of inventory is low and the
cost control need to be minimizing control is base up on the judgment of the
individual and the period review of the item being ordered.
Two –bin system: the two bin system divides each items of inventory in to two
groups or bins. In the first, a sufficient supply is kept to meet current demand
over designed period of time, in second; enough additional items are available to
meet the demand during the lead time necessary to fill being order. The advantage
of this form of control is minimum control expense and positive physical
recognition of reorder points. The principal disadvantages are the limited
information available regarding inventory status of items, lack of monthly usage
date and reliance on store room personal.
Periodic order system: under this system, the stock level for all inventory
accounts are reviewed at established interval and orders and placed to bring all
accounts up to their maximum level. Since, order are automatically placed, at the
reviewed periods the system greatly simplifies the ordering process.
This advantage may however, sometimes be a disadvantage because of heavy
paper work burden it places periodically on purchasing department.
2.14Method for Determining Material Requirement
As the ultimate goal of inventory control program is to provide maximum customer service at
minimum cost, the organization must select a method of determining material requirement that is
suitable for its operation. The following are the most important points that must be taken into
account.
Explosion process: In many manufacturing organization material requirements are
relies on directly on sales forecast. For each of its product the company prepares a
bill of materials a list of parts (and their quantities) needed for various products to
determine the overall material requirements.
Past usage method: Inventory or material requirements are relies on past usage
rather than on the sales forecast. If a creasing item were used at rate of 100 units
per month during the past year or using some other representative period, it is
likely to be use at the same rate in future.
26
Change in product mix or product design may adversely affect the results of the
usage method
Value volume analysis: Many organization use value volume analysis to
determine which inventory account should be controlled by explosion method and
which should be controlled by past usage method.
Those items with a high level of activity must be more closely controlled than the ones with
relatively low activity levels. Their requirements must be determined by accurate explosion
process. While requirements for low activity items can be determined by the accurate and less
costly past usage method (Bhalla, 2000).
Regardless of the inventory system in use, record accuracy is crucial to its success. One method
of achieving and maintaining accuracy is to assign responsibility to specific employee for issuing
an receiving materials and accurately reporting each transaction. A second method id to secure
inventory behind locked doors or gates to prevent un authorize or un reported with dowels. This
method also guard’s receipts in the wrong authorize or un reported with dowels. This method
also guards receipts in the wrong locations, where they can be lost for months.
Cycle accounting is a third method, whereby, store room personnel physically count a small
percentage of the total number of items each day, correcting errors that they find. Class a times
counted most frequently. A final method for computerized systems is to make logic error checks
on each transaction reported and fully investigate any is discrepancies. Discrepancies may
include:
receipts with an in accurate (non existence) part number (Kpajewski & Pitzman, 2002).
27
2.16 Inventory /Stock Turn Over
Stock turnover ratio tells how many times in year stock are used up and replaced. The greater the
stock over, the more efficient is the stock policy. High stocks turn over saves money and it is
thus an indicator of efficiency.
Stock turnover ratio is an indicator of the rate of consumption: i.e. the fast moving and slow
moving materials. A high inventory turnover ratio indicates fast moving materials and low ratio
indicates slow moving materials. The tarn over of different materials may be compared to detect
those items which do not move regularly. This will enable the management to avoid keeping
capital locked up in undesirable items of materials. Stock turnover rate may also be calculated in
terms of days. This is done by dividing 365 days by inventory turnover ratio.
Days in years
Stock turnover in terms of days= Inventory turnover
If the length of stock turnover period is short, the material is considered to be fast moving, and if
the length of stock turnover period is long, the material is considered to be slow moving. The
stock turnover is a good measure of the efficiency of material utilizations (Arora, 2003:52)
28
CHAPTER THREE
3. RESEARCH METHODOLOGY
3.4.1 Questionnaires
Questionnaires have been widely used for descriptive and analytical surveys in order to find out
facts, opinions and views (Naoum, 2007).
29
In this study, the questionnaires were designed to get the factual information about local
inventory and construction resource management practices of the company. The questionnaires
consisted of two parts. The first part described the demographic profiles of the respondents and
the second part portrays 49 closed ended queries, which were presented in a table using a Likert
scale ranging from 1=strongly disagree to 5= strongly agree. Likert scale was employed to
describe the responses of the closed questions quantitatively.
3.4.2 Interview
A first general principle in data collection was that the inclusion of multiple sources of data
collection in a research project is likely to increase the reliability of the observations. Denzin
(1978) coined the term triangulation to refer to the use of multiple methods of data collection. As
Kvale (1996: 14) remarks, as an inter-view, an interchange of views between two or more people
on a topic of mutual interest, sees the centrality of human interaction for knowledge production,
and emphasizes the social situations of research data. For the purpose of triangulation, this study
used structured interview to collect pertinent information from two purposefully selected
respondents (branch office manager and logistics manager) because they were known the
administration systems inventory management in directly and indirectly.
30
Less than 1.45 strong disagreements on the items in each category.
Qualitative data analysis involved organizing, accounting for and explaining the data; in short,
making sense of data in terms of the participants’ definitions of the situation, noting patterns,
themes, categories and regularities. The data collected through interview and documents are
analyzed qualitatively and summarized in words.
31
CHAPTER FOUR
As depicted in the table 93.75% of the respondents are males and 6.25% are female. This
indicates most of the human resource working in the branch office is dominated by males. As
shown in above table the occupations of the respondents 27.78% are store man, 22.22% are
32
engineers, 16.67% are accountants and 11.11% are managers, auditors and purchasers each
respectively. This indicates most of the respondents are store man. As depicted in the same tables
83.33% of the respondents are first degree holders, 11.11% are in diploma level and the
remaining 5.56% are 2nd degree holders. This indicates most of the human resources in the
branch office are educated. On the same table the respondents were also asked to indicate
whether they have experience on their job. The study shows that 77.78%are above five years,
16.67% are four years experience and 5.56% are one year work experience. This shows the
majority of the employees have at least five year experience in their respective occupations.
2 The policies and procedures are current, in writing, and properly approved. 3.53 0.96
3 These policies and procedures are clearly stated and systematically 3.6 0.94
communicated to the respective departments.
As one can understood from the above table, the mean score X = 4.00 shows the respondents
expressed their agreement that the organization has inventory policies, procedures and manuals
with the least response variation as compared to the other items. The mean score X =3.88 shows
the agreement of the respondents concerning receiving, issuing, accounting and storing
responsibilities are properly segregated for the responsible departments. Moreover, the
respondents have shown their agreement on these policies and procedures in supporting the
internal control system of the office with mean score 3.71 and slight response variation among
themselves. The respondents of this study have shown their agreement that these policies are
clearly stated and are systematically communicated to the respective departments with mean X
= 3.6 and relatively higher response variation. Finally, the respondents have shown their accord
on the policies and procedures confirming they are current in writing and properly approved with
33
the least mean score X =3.53 and the highest response variation as compared to the other items..
In general, the agency has its own currently written, well approved, inventory policies,
procedures and manuals, which are systematically communicated to the respective departments.
This means each department has implemented its own inventory Policies and Procedures in a
better and organized way based on their level of activities. Therefore, the agency used these
policies, procedures and manuals in each departments to support its internal controlling system
by making the inventory management documents (Receiving, issuing, accounting and storing
responsibilities) familiar to its employees. As described by Miller (2010) an inventory system is
the set of policies that controls and monitors inventory level and determine what level should be
maintained, how large orders should be made and when stock should be replenished. Hence,
having policies and manuals help the office in performing inventory controls.
Table 4.3 Inventory Control mechanisms
Items Mean S.D
1 The management takes the appropriate steps to safeguard goods against risk 2.76 1.41
of loss by theft (e.g., goods kept in locked buildings, rooms, or cages, access
to which is granted only to authorize personnel).
2 Inventory records are reconciled (and differences explained) to advantage 3.90 1.28
reports on a regular basis. (Current inventory is adjusted at year-end by
fiscal year-end physical counts.)
3 Departments compare quantities received against receiving reports 2.82 1.05
4 Materials are released from storerooms only on the basis of requisitions 3.88 0.92
which are approved by a responsible official of the department.
5 Adequate provisions are made for obsolete and inactive items in 3.06 1.12
inventories.
year-end by fiscal year-end physical counts with mean score X =3.90 and materials are released
from storerooms based on a formal request for official services and approved by a responsible
person in each department of the agency with the highest mean score X =3.88 and least response
variation(S.D= 0.92). This indicated us the agency implemented efficient material management
and effective control of inventories that help to achieve better operational results and reduce the
34
risk of construction material loss or working capital on annual basis. It has a significant influence
on the profitability of the agency. Meanwhile, the respondents were not willing to give their
opinion(since the mean scores fall in the interval from 2.45 – 3.45 undecided) concerning the
risk taken to prevent loss or theft (Item 1 with X = 2.76), comparison of quantities received
against receiving reports (Item 3 with X = 2.82) and the provisions made for obsolete and
inactive items in inventories (Item 5 with X = 3.06). Since sufficient information is not given on
these items it is very difficult to explain the inventory control system of the branch office at this
stage. Even though the respondents confirmed the existence of inventory policies and manuals to
conduct inventory in the organization and are communicated for each department, the writer of
this study is suspicious on the practical use of these documents. Arora (2000) described that the
accounting control of materials is concerned with safeguarding of undertakings property in the
form of materials by proper recording of receipt and issuance and balance in the stock.
35
Table 4.4 Inventory Handling Systems
Items Mean S.D
1 Procedures for physical counts provide the use of adequate written instructions. 2.41 0.95
2 Procedures for physical counts provide a room for adequate supervision. 3.94 0.94
3 The procedures for physical counts provide for clearly marking damaged and obsolete 3.76 0.91
inventory.
4 The procedures for physical counts provide for the use of pre-numbered tags which are 2.29 1.03
accounted for.
5 The procedures for physical counts provide for the counting of the items and access to 2.17 0.76
the tags only by employees who are not responsible for custody of the particular items.
6 The procedures for physical counts provide for the rechecking of counts and 3.58 1.29
descriptions (dual counts) where perpetual records are not maintained and where
variations from the perpetual records are significant.
7 The procedures for physical counts provide for careful investigation of significant 3.52 1.30
overages and shortages.
8 The procedures for physical counts provide for prompt adjustment of records for 2.11 0.99
inventory discrepancies after approval by a responsible official other than stores
personnel.
9 The procedures for physical counts provide for recording counts on permanent 3.82 0.93
inventory count sheets.
10 The procedures for physical counts provide for the signing and dating of inventory 3.70 1.33
count sheets by the person supervising the count.
11 The procedures for physical counts provide for properly accounting for goods that are 4.00 0.88
consigned in and out.
12 The management reviews the reconciliation of physical inventory counts to the 3.88 0.93
inventory records.
13 Adequate provisions are made for cut-off of receipts and issues. 3.41 1.01
14 If applicable, issuing and billing procedures are designed and correlated so as to ensure 3.64 1.06
the billing of all items
15 There is physical segregation and proper accounting control of merchandise on hand 2.35 0.86
that is not property of the entity.
(Source: Researcher’s Survey)
As it depicted in the above table the respondents have reflected their agreement on the inventory
36
handling systems of the organization for most of the items related to procedures for physical
counts. According to their responses the procedures for physical counts have provided the
opportunity for properly accounting the goods that are consigned in and out (with mean X
=4.00), provided a room for adequate supervision (with mean X =3.94), helped the management
to make reviews and reconciliation to the inventory records (with mean X =3.88), helped the
organization in recording counts on permanent inventory count sheets (with mean X =3.82), were
used for clearly marking damaged and obsolete inventory (with mean X =3.76), helped to clearly
see the signing and dating of inventory count sheets by the person supervising the count (with
mean X =3.70), were applicable in issuing and billing procedures are designed and correlated so
as to ensure the billing of all items(with mean X =3.64), the physical counts were useful in the
process of rechecking of counts and descriptions (with mean X =3.58) and helped to make
careful investigation of significant overages and shortages(with mean X =3.52) with slight
response variations respectively. On the other hand, the respondents have reflected their
disagreement on the use of the procedures of physical counts in adequate written instructions
(with mean X =2.41) and the use of pre-numbered tags which are accounted for the counting of
the items and access to the tags only by employees who are not responsible for custody of the
particular items (with mean X =2.29 and X =2.17 respectively). They have also insisted their
of the entity(with means X =2.11 and X =2.35 ). Finally, the respondents hesitated to show
their position regarding the role of the procedures for physical counts in adequate provisions for
cut-off of receipts and issues (with mean X =3.41). Generally, the employees’ response reflected
the use of physical counts of inventories for different purposes. As far as Bhalla (2000) is
concerned there are five types of control devices that are used inventory handling system.
Among these Physical counting is the one where all companies take periodic inventory at least
ones each a year.
Physical counting of stock on hand necessary for tax, cost accounting functions gives a room for
adequate supervision and provide for careful investigation of significant overages and shortages.
37
Table 4.5 Perpetual Inventory Systems
Items Mean S.D
1 Detailed perpetual inventory records are periodically reviewed for slow- 2.29 0.91
moving items.
2 A perpetual inventory system is (including quantities and value) in use as to 3.41 1.16
all major classes of inventory.
3 Perpetual inventory records are updated promptly. 3.52 1.16
4 The postings to the perpetual inventory records made promptly are from 2.41 1.05
Pre-numbered, signed receiving reports.
5 a. The postings to the perpetual inventory records are made promptly from 3.56 1.14
issue requisitions.
6 In additions to perpetual inventory, records are referenced to supporting 3.88 0.84
invoices to insure easy verification of the records.
7 Inventories are taken without prior reference to quantities on perpetual 2.35 0.93
records.
8 There are discrepancies between physical counts and perpetual records 3.58 0.95
investigated and resolved.
(Source: Researcher’s Survey)
As shown in the above table the mean scores X =3.88, X =3.58, X =3.56 and X =3.52 with
their minor differences among the respective standard deviations have shown their agreement on
the use of perpetual inventory systems are referenced to supporting invoices to insure easy
verification of the records, helped the organization to identify discrepancies between physical
counts and perpetual records investigated and resolved, gave chance to review posts using
requisitions and update helped to update the records promptly. On the other hand, the
respondents reflected their disagreement concerning regular inventory records of slow –moving
items (with X =2.29). That means, regular inventory records are not made for slow-moving
items in this organization. Similarly, the perpetual inventory records made promptly are not from
Pre-numbered, signed receiving reports (with X =2.41) and inventories are not taken without
prior reference to quantities on perpetual records (with mean X =2.35). Concerning the usage of
perpetual inventory to all major classes of inventory the respondents position is neither
agreement nor disagreement (with mean X =2.41). When the remaining responses are examined
4 In the organization materials received last are issued first (Last in first out). 2.35 0.88
5 In the organization materials issued are priced at the weighted average cost 3.64 0.82
of material in stock (Weighted average cost method).
6 In purchasing materials the organization takes anticipated market trends, 3.76 0.83
transportation charges, and normal quantity of purchase into consideration
(Standard price method).
(Source: Researcher’s Survey)
As shown Table 4.6 the mean scores X =3.76, X =3.64, X =3.58 and X =3.52 with their minor
differences among the respective standard deviations the respondents have shown their
agreement on the different usage of inventory control techniques by the branch office. According
to the magnitudes of the mean scores, standard price method, weight average cost method and
First in First out (FIFO) method are in practice in this organization. Furthermore, the respondents
indicated that the highest value items are under the tight control and under responsibility of the
most experienced personnel. They are unable to decide concerning the use of ABC analysis of
Inventories. As the function of this method is to control high valued items than low valued items,
it can be said that this method is also applied in some extent since respondents have shown their
agreement on Item (2).
39
In conclusion, the agency focused first on the items that require the most frequent attention, thus
ensuring that there are enough of these items on hand when needed. Items that require less
attention are focused on next, and items that require the least amount of attention are focused on
last. This grouping of items help the agency to improve overall material availability while
reducing excess and obsolete material, focus on material with the highest value effect, minimizes
the probability and severity of stock outs, and use effectively inventory management staff time.
Therefore, the agency control high value items more closely than low value items. This allows
the agency to overcome poor planning and control of materials, lack of materials when needed,
poor identification of materials, re-handling and inadequate storage cause losses in labor
productivity and overall delays that can indirectly increase total project costs. These findings are
supported by literature. Bhalla, (2000) pinpointed that those items with a high level of activity
must be more closely controlled than the ones with relatively low activity levels. Their
requirements must be determined by accurate explosion process. While requirements for low
activity items can be determined by the accurate and less costly past usage method. One way or
the other the organization is not using a single inventory controlling technique. Using different
inventory controlling technique may help to compensate the drawbacks of the techniques and
exploit their advantages.
Table 4.7 Stock evaluation & performance measurement
overall inventory system (with mean X = 3.58) and regular auditing inventory practice of the
40
Meanwhile, the respondents have shown their disagreement on the arbitrary target setting (with
mean X = 2.35) and in giving priority for Inventory Record Accuracy (with mean X = 2.23).
Finally, the respondents were unable to share views regarding strong cycle counting program,
which leads to complete or partial elimination of the annual physical inventory with its high
In general, the agency used such stock evaluation & performance measurement to complete or
partial elimination of the annual physical inventory problems that are preventing the store man
from risks, to know the kind and numbers of items in the store, to identify usable and despoiled
materials. This shows that having stock evaluation & performance measurement in the agency
prevented the overall inventory managing systems of the agency. These create problems of
knowing the amount and specific numbers of materials in the storerooms and create problems of
inventory management.
Table 4.8 Inventory management constraints
Items Mean S.D
1 The organization has a storage problem in its stock management system. 4.18 0.85
2 There are significant losses of construction materials in the company due to 3.65 0.80
lack of quality production by industries/producers.
3 The organization respective departments have qualified personnel who can 3.18 1.09
properly manage their duties in inventory handling.
4 Due to work overload the organization has a problem of delivering inventory 3.82 0.99
reports to the regional housing and construction Agency.
5 The organization has a day to day recording system of stock and bin card. 2.70 1.15
(Source: Researcher’s Survey)
As the above table shows, the mean score X =4.18 signifies the respondents agreement that the
agency has a storage problem in its stock management system with a slight response variation.
The mean score X =3.82 for item(4) shows the respondents agreement on the reporting problem
to the regional housing and construction Agency due to work overload with the least response
variation as compared to the other items. In addition, the mean score X = 3.65 revealed
agreement among the respondents regarding significant losses of construction materials in the
company due to lack of quality production by industries/producers. On the other hand the mean
score X =3.18 for item (3) describes the respondents were unable to decide concerning the
41
organization respective departments have qualified personnel who can properly manage their
duties in inventory handling. In addition to these, the mean score X = 2.70 for item(5) shows the
respondents were unable to give their opinion (undecided) concerning the organization day to
day recording system of stock and bin card with the highest response variation as compared to
the other items. These means the agency may not use systems of records, so the storekeeper and
the respective departments have faced problems of quantitative record of stores materials and
their cost, receipt, issue and balance of each item in the store. Dainty et al. (2001) explain that
the construction sector faces wide fluctuating demand cycles, project-specific product demands,
uncertain production conditions, and there are also evidences of a combined diverse range of
professional skills. This might be the reason the respondents rated these items as problems in the
branch office. Thomas et al. (2002) also define problems in the flow of equipment and
information is critical to improve the productivity in the construction sector. They also indicate
that potential improvement areas are widely found in both the planning of how to organize the
construction site and of the logistic of the building itself. Some of these inventory management
constraints are mentioned in some studies. Inventory management in construction project could
be affected by several factors such as; inadequate storage space (Sardroud, 2012), over ordering
and double handling (Donyavi & Flanagan, 2009); and incomplete and lack of up-to-date
information regarding on-site stock (Navon & Berkovich, 2006).
Both the branch manager and the logistic manager were responded as the agencies have policy,
procedures and inventory manuals. From this it is possible to conclude that even though the
agency followed the regional inventory management policy, procedures and inventory manuals,
it may faced to some gabs because the context of various organization is different and need its
42
own context of implementing activities more specifically based on its rules and regulations, so
the agency cannot make it.
For this question, the manager responded that as his organization has its own inventory control
systems. That were implemented by setting committee and by providing unique activities for
auditors to count and check through inspection. On the other hand, the logistic manager was
expressed as the agency partially follows its own Inventory Control Systems. Among them
receiving, issuing, accounting and storing materials were properly implemented by the
responsible departments in the agency.
The branch manager responded that his organization was implemented different inventory
handling systems. When materials are needed immediately to release from the store, the one who
wants to get the material issuing them and give it to his boss and logistic manager for approval.
As that time, the store person checked whether the materials were present in the store or not.
After that based on model 19 the materials were released from the store by putting his/her
signature on it. The logistic managers also assure this idea by saying when materials were
needed by some body, first checked its availability in the store or it purchased by the concerned
body and then the person who need that materials issued them by stating for what purpose do
he/she want to use them. After the person had got approval for the responsible body and then
he/she took the materials by putting his/her signature on model 19.
The branch manager responded that counting materials were implemented in his organization
once a year in June. The purpose of counting materials at this month was that to know the
amount of materials in the coming year and to identify which materials can be functional and
which one spoiled. The logistic managers also answered that to identify the amount of materials
based on their items the agency counted them annually. However, the agency also counted
materials unexpectedly, when the organization believed the store person have faced the
organization to various problems.
The manager expressed that the agency did not implemented all material controlling techniques
in the best way, but we try to use some of them. Similarly, the logistic manager was stated that
the agency used different material controlling techniques, but the store persons have their own
workloads and lack of time due to that they could not use all of them. Because of that, the store
persons developed and used their own controlling systems which are comfortable for them.
43
The branch manager responded that his organization evaluated it’s stoke materials based on the
counting reports of auditors and by observing them in the store. The logistic managers also stated
that as they were observing the store and checked which material items have enough storage and
which items have scarcity and take any necessary measures. In addition to these frequently
observation and evaluating stoke materials the agency also apply counting these materials
annually.
The branch manager stated that, there were many problems that affect inventory management in
his organization among them: the agency used so many kinds of construction materials due to
that they had lack of enough store to identify and put them based on their items, problems of
getting quality materials in the market, problems of workload and having enough number of
store persons were some of the main obstacles that affect their inventory management systems in
the agency.
The logistic manager also assured that the agency is one of the huge construction offices in the
region, so it used various items and many numbers of construction materials. As a result, the
agency faced to problems of store and put them on the field. When these materials were found on
filed they spoiled by sun and rain. In addition to this, they faced to theft. The agency also has
lack of store person, so those who were working became loaded by various works and unable to
record their daily stoke balance. Consequently, they have problems of preparing reports when the
responsible bodies needed it.
44
CHAPTER FIVE
5.1 Summary
This study attempted to assess the inventory management practice of Amahara National Regional
State Construction and Housing Development Agency Dessie City Branch Office. The type of
research design was descriptive survey. The study employed both quantitative and qualitative
methods (mixed method). The total number of the target population was 54 among which 18
participants were selected using purposive sampling. Two employees of the office were also
purposively selected for an interview (Branch manager and logistic manager). The data were
collected through questionnaire, interview and document analysis. The quantitative data were
collected through self rated questionnaire where the items are rated using Likert Scale ranging
from 1= strongly disagree to 5=strongly agree. The items are 49 in number, which are
categorized into seven groups. Seven generalized questions were designed for the interview.
Necessary documents that are essential to carry out inventory management were examined to
perform the document analysis. The quantitative data was analyzed using mean scores and
standard deviations by categorizing the mean scores into intervals. The qualitative data collected
through interview and document analysis were analyzed in word and paraphrased.
In order to assess the inventory management practice of the branch office the following four
questions were foreshadowed and investigated.
According to the analysis the inventory controlling mechanisms of the branch office are found to
be:
Materials are released from storerooms only on the basis of requisitions which are
approved by a responsible official of the department.
Inventory records are reconciled to advantage reports on a regular basis and current
inventory is adjusted at year-end by fiscal year-end physical counts.
2) What are the strategies being followed by the agency in overcoming the problems of
inventory?
45
In purchasing materials the organization uses Standard price method and takes
anticipated market trends, transportation charges, and normal quantity of purchase into
consideration
The organization also uses weighted average cost method where materials issued are
priced at the weighted average cost of material in stock.
In the organization the highest value items are under the tight control and under
responsibility of the most experienced personnel.
In the organization Materials received first are issued first (First in first out).
As shown above the organization is not using a single inventory controlling technique. Using
different inventory controlling techniques may help to compensate the drawbacks of the
techniques and exploit their advantages.
3) What constrains or a bottleneck does inventory management system face in the day to day
organizational activities?
There are significant losses of construction materials in the company due to lack of
quality production by industries/producers.
Due to work overload the organization has a problem of delivering inventory reports to
the regional housing and construction Agency.
4) What are the systems the agency uses to record, store retrieve and generate reports of
inventory?
4.2 Conclusion
This paper has presented a brief overview of inventory management practices on Amahara
National Regional State Construction and Housing Development Agency Dessie City Branch
Office. It intended to provide a short and precise conclusion and implications of findings. A
conclusion is done to indicate the outcome of the study and forward implications.
However, the agency has its own currently written, well approved, inventory policies, procedures
and manuals, which are systematically communicated to the respective departments. This means
each department has implemented its own inventory Policies and Procedures in a better and
organized way based on their level of activities. Therefore, the agency used these policies,
procedures and manuals in each departments to support its internal controlling system by making
the inventory management documents (Receiving, issuing, accounting and storing
responsibilities) familiar to its employees. According to the respondents, sufficient information is
not given on these items it is very difficult to explain the inventory control system of the branch
office at this stage. Even though the respondents confirmed the existence of inventory policies
and manuals to conduct inventory in the organization and are communicated for each
department, the writer of this study is suspicious on the practical use of these documents. In
addition to these, the employees’ response reflected the use of physical counts of inventories for
different purposes.Even though most business was small and uncomplicated; this control system
was used in all types of operation manufacturing, service, whole sale, and retail. It is time based
operation which involves scheduled periodic review of the stock level of all inventory items,
stock levels can be monitored by physical inspection, by visual review of perpetual inventory
cards, or by automatic computer surveillance. In most operation perpetual record is maintained.
According to the respondents, the agency focused first on the items that require the most frequent
attention, thus ensuring that there are enough of these items on hand when needed.
Items that require less attention are focused on next, and items that require the least amount of
attention are focused on last.
The major of the respondents agree with the agency used such stock evaluation & performance
measurement to complete or partial elimination of the annual physical inventory problems that
are preventing the store man from risks, to know the kind and numbers of items in the store, to
identify usable and despoiled materials. This shows that having stock evaluation & performance
measurement in the agency prevented the overall inventory managing systems of the agency.
47
These create problems of knowing the amount and specific numbers of materials in the
storerooms and create problems of inventory management. In addition, the agency may not use
systems of records, so the storekeeper and the respective departments have faced problems of
quantitative record of stores materials and their cost, receipt, issue and balance of each item in
the store
5.3. Recommendation
Based on the major findings and conclusions the following recommendations were forwarded to
Amahara National Regional State Construction and Housing Development Agency Dessie City
Branch Office and other stakeholders.
Effective inventory management is recognized, as one of the areas management of any
organization should acquire. The ability of any organization to evolve effective inventory
management system will depend on the extent to which it perceives the benefits it stands
to gain from such program.
Even though the agency used the regional inventory management policy, procedures and
manuals, it faced to some gaps. That is due to its context is differ from the other
organizations’ in the region and need its own conditions for implementing activities
more specifically based on its rules and regulations, so the researcher recommended the
agency to have its own inventory policies, procedures and manuals rather than using the
others.
Providing unique activities for auditors to count and check through inspection. It also
controls its stock by taking physical counts annually for the advantage of reports at the
end of the fiscal year. As a result, problems with the inventory do not correct until the
count could do, typically at the end of the fiscal year, so the agency should improve its
inventory control systems.
In addition to this, although the agency try to minimize the loss of materials by using
periodic inventory records and annual physical counts, it did not take appropriate steps to
safeguard goods from risk of loss by theft because its department could not compare
quantities received against receiving reports. Therefore, the managers should encourage
and control the concerned department to implement inventory controlling systems
properly and solve these problems.
48
Even though the agency had so many strong sides in having written instructions and
procedures to provide physical counts, it had some weakness to make them familiar and
applicable all of them by its employees. Therefore, the agency had faced to some
problems of inventory handling systems in its day-to-day activities because of those
employees who did not implement the agency’s written instructions and procedures that
enable them to provide physical counts. As a result, the agency should make more
familiar its policy, procedures and manuals to its employers and improve their inventory
handling system.
As some of the respondents stated that, perpetual inventory records did not periodically
review to detect slow moving. This means the work of recording an inventory did not
implement properly by the concerned bodies. Thus, it could be difficult for the manager
to make correct decisions about the disposal, replacement, or discontinuance of different
segments of the inventory base. To solve problems of Perpetual Inventory Systems, the
agency should take its own measures.
According to the research participants, the agency used different material controlling
techniques, but it did not implement all of them in the best way due to store persons
workloads and lack of time. Because of that, the store persons sometimes developed and
used their own controlling systems, which are comfortable for them. Therefore, the
researcher recommended that the agency should add store personals to reduce their
workload and create comfortable conditions to implement all inventories control
techniques.
The agency used stock evaluation & performance measurement to complete or partial
elimination of the annual physical inventory problems that are preventing the store man
from risks, to know the kind and numbers of items in the store, to identify usable and
despoiled materials.
This shows that having stock evaluation & performance measurement in the agency
prevented the overall inventory managing systems. However, respondents stated that the
agency did not give priority for accurate recording of inventories to assure material
availability when orders are released. These create problems of knowing the amount and
specific numbers of materials in the storerooms and create problems of inventory
management. Therefore, the agency should take measures to solve this problem.
49
Most respondents stated that the agency faced to problems of storeroom, put materials on
the field, and spoiled by sun or rain, problems of identifying and putting materials based
on their items and created over workload on the concerned body in order to deliver
inventory reports to the regional housing and construction Agency. Due to that, it faced
to significant losses of construction materials. To solve this problem of inventory
management the agency should fulfill with appropriate personals and built enough store
rooms.
50
References
Agresti A. (2002). Categorical data analysis (2nd ed.). Hoboken, New Jersey: John Wiley &
Sons. Bloom N., and Reenen J. V. (2009) ‘Why do management practices differ
Burns, N. & Grove, S.K., (1987). The practice of nursing research. W.B. Saunders Company,
Philadelphia.
Dainty, Andrew R.f., Briscoe, Geoffrey H., and Millett, Sarah f., 2001. New perspectives on
construction supply chain integration. Supply Chain Management: An International
Journal. Volume 6 (4), page 163-173
Donyavi, S. & Flanagan, R. (2009). The Impact of Effective Material Management on
Naoum, S, (2007). Dissertation research and writing for cons traction students, Oxford:
Butterworth – Heinemann.
Nasir, H. (2008). A Model for Automated Construction Materials Tracking. University of
Waterloo: Master Thesis.
Navon, R. & Berkovich, O. (2006). An Automated Model for Materials Management and
Materials and Components. Journal of Scientis Iranica A, vol. 19(3), pp. 381-392.
Thomas, H. Randolph. Horman, Michael J., de Souza, Ubiraci Espinelli Lemes. and Zavřski,
144-154
Self Report Questionnaire to be filled by Dessie City Housing and Construction Branch
Office Employees
This questionnaire is part of a research project used to examine and explore the inventory
management practice by Dessie City Housing and Construction Branch Office. The worth
of the study completely depends on the true and factual answers you provide. Therefore,
you are kindly asked to fill in the questionnaire, honestly, genuinely and carefully. I would
like to stress that the information you provided is completely confidential and used by the
researcher only. For that matter, you don’t have to write your name.
Thank you in advance!!!
General instruction: There are two parts in this questionnaire. The first part is about
personal information and the second part is about close ended questions.
Part II: The following table consists of a listing of inventory management and control systems
that might have been practised in your company. For each item a Liker scale of one (1) to five
(5) is given. Rate your agreement on the listed items using:
1= Strongly Disagree
2= Disagree
3= Undecided
4= Agree
5= Strongly Agree
Direction: Put “” sign in the table
No.
Inventory policies and procedures 1 2 3 4 5
1 The organization has Inventory policies, procedures and manuals..
2 The policies and procedures are current, in writing, and properly approved.
9 Materials are released from storerooms only on the basis of requisitions which
are approved by a responsible official of the department.
10 Adequate provisions are made for obsolete and inactive items in inventories.
13 The procedures for physical counts provide for clearly marking damaged
and obsolete inventory.
14 The procedures for physical counts provide for the use of pre-numbered
tags which are accounted for.
15 The procedures for physical counts provide for the counting of the items
and access to the tags only by employees who are not responsible for
custody of the particular items.
16 The procedures for physical counts provide for the rechecking of counts
and descriptions (dual counts) where perpetual records are not maintained
and where variations from the perpetual records are significant.
17 The procedures for physical counts provide for careful investigation of
significant overages and shortages.
18 The procedures for physical counts provide for prompt adjustment of
records for inventory discrepancies after approval by a responsible official
other than stores personnel.
19 The procedures for physical counts provide for recording counts on
permanent inventory count sheets.
20 The procedures for physical counts provide for the signing and dating of
inventory count sheets by the person supervising the count.
21 The procedures for physical counts provide for properly accounting for
goods that are consigned in and out.
22 The management reviews the reconciliation of physical inventory counts
to the inventory records.
No.
Perpetual Inventory Systems
Detailed perpetual inventory records are periodically reviewed for slow-
26 moving items.
A perpetual inventory system is (including quantities and value) in use as
27 to all major classes of inventory.
29 The postings to the perpetual inventory records made promptly are from
Pre-numbered, signed receiving reports.
30a. The postings to the perpetual inventory records are made promptly from
issue requisitions.
31 Additions to perpetual inventory records are referenced to supporting
invoices to insure easy verification of the records.
34 The organization uses the ABC analysis of Inventories (in this approach of
inventory control high value items are more closely controlled than low
value items).
35 The highest value items are under the tight control and under
responsibility of the most experienced personnel.
36 In the organization Materials received first are issued first (First in first
out).
37 In the organization materials received last are issued first (Last in first
out).
38 In the organization materials issued are priced at the weighted average cost
of material in stock (Weighted average cost method).
39 In purchasing materials the organization takes anticipated market trends,
transportation charges, and normal quantity of purchase into consideration
(Standard price method).
አባሪ 12
የንብረት ገቢና ወጪ መመዝገቢያ መዝገብ
ቁጥር-------------
ቀን----------------
የመ/ቤቱ ስም ------------------------
የተቆጠረበት ቀን ----------------
አበሪ 19
የቋሚ ንብረት በር መውጫ ፈቃድ
ቁጥር -------------------
ቀን ---------------------
የመስሪያ ቤቱ ስም ----------------------
ለጥገና
ለስራ ጉዳይ
------------------------ በትውስት
ማሳሰቢያ፡- ቅፁ በ 3 ኮፒ ተዘጋጅቶ፣
የእቃ ወጪ መጠየቂያ ቅጽ
የብሎክ ቁጥር
የህንጻው አይነት
የግንባታ ሳይት ቀን
ብዛት
ተ .ቁ ዕቃው ዝርዝር መለኪያ ምርመራ
የተጠየቀው የተፈቀደ
ፊርማ ፊርማ
ቀን ቀን
የፈቀደው ኃላፊ ስም
ፊርማ
ቀን
ደሴ፤
እኔ ለ አገልግሎት ሚውል
ከዚህ በታች የተዘረዘሩትን እቃዎች እንዲፈቀድልን አመለክታለሁ፡፡
ፊርማ ፊርማ
ቀን ቀን
ከደሴ ከተማኮን/ቢ/ል/ኤጀንሲ የንብረት ቆጠራ የዕቃ መዘርዘሪያ ቅጽ መደበኛ
ቀን
ቀን ቀን