Theobroma - Supply Chain
Theobroma - Supply Chain
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Theobroma store HSR layout
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Theobroma store HSR layout
LIST OF TABLES:
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TABLE OF CONTENTS
Product Categorisation based on perishability................................................................... 2
TABLE OF CONTENTS.......................................................................................................................3
CHAPTER 1........................................................................................................................................... 4
THEOBROMA.......................................................................................................................................4
1.1. Inventory Management system...................................................................................................4
1.2. About the brand.......................................................................................................................... 4
1.3. Store Location.............................................................................................................................5
1.4. Categories and Product Assortment........................................................................................... 6
1.5. Store online presence:...............................................................................................................10
CHAPTER 2......................................................................................................................................... 11
INVENTORY ANALYSIS:..................................................................................................................11
2.1. Store Space and capacity:......................................................................................................... 11
2.2. Product Categorisation based on Ultra-perishable, perishable , Non-perishable :................... 11
2.3. Inventory management system:................................................................................................ 11
2.3.1.First-In, First-Out Inventory Control Technique:.............................................................11
2.3.2 Inventory Control system - PERIODIC........................................................................... 12
2.3.3 Inventory Tracking technique - ( Point on sale system ) :............................................... 12
2.4 Order cycle :.............................................................................................................................. 13
2.5 Stock replenishment :................................................................................................................ 13
2.6. Inventory control measure :......................................................................................................13
2.6.1. Demand Forecasting:...................................................................................................... 13
2.6.2. Time Horizon:................................................................................................................. 14
2.6.3. Safety Stock:................................................................................................................... 14
2.6.4. Dead Stock:..................................................................................................................... 14
2.6.5. Reorder Quantity:............................................................................................................15
2.7. Inventory management - logistics and lead time :....................................................................15
2.7.1 Logistics at Theobroma:...................................................................................................15
2.7.2. Lead Time at Theobroma:...............................................................................................16
2.8 Distribution strategy:................................................................................................................. 16
2.9. Supply chain strategy:.............................................................................................................. 17
2.10. Challenges:............................................................................................................................. 18
2.10.1. Perishability and Spoilage:............................................................................. 18
2.10.2. Demand Fluctuations:.................................................................................... 19
2.10.3. Supply Chain Disruptions:.............................................................................. 19
Conclusion:......................................................................................................................................20
Annexure - Questionnaire :..............................................................................................................21
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CHAPTER 1
THEOBROMA
An Inventory Management System (IMS) is a strategic tool designed to oversee and control
the acquisition, storage, movement, and utilization of inventory within an organization. From
a management perspective, it serves as a centralized platform to ensure optimal inventory
levels, minimize costs, and enhance operational efficiency. The system provides real-time
visibility into stock levels, streamlines procurement processes, and supports data-driven
decision-making to align inventory with business objectives, customer demand, and financial
goals. By automating inventory tracking, forecasting, and reporting, an IMS enables
managers to maintain a balance between overstocking and stockouts, ultimately improving
profitability and customer satisfaction.
Theobroma is a renowned Indian bakery and patisserie chain celebrated for its delectable
brownies, cakes, and a variety of European-style desserts. Established in 2004 by sisters
Kainaz Messman Harchandrai and Tina Messman Wykes, the brand has grown from a single
outlet in Mumbai's Colaba neighborhood to a widespread presence across major Indian cities,
including Mumbai, Pune, Delhi NCR, Hyderabad, and Bengaluru.The name "Theobroma" is
derived from Greek, meaning "food of the gods," which is also the scientific name for the
cacao tree. This reflects the brand's dedication to crafting divine and indulgent treats.
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Fig 1.1 Theobroma brand logo
Over the years, Theobroma has experienced significant growth. Starting with an initial
investment of ₹1 crore, the company expanded its operations and, as of recent reports, has
achieved a valuation of approximately ₹3,500 crore. This remarkable journey underscores the
brand's commitment to quality and customer satisfaction.
In addition to its core offerings, Theobroma has diversified its menu to include a range of
products catering to various tastes, solidifying its position as a beloved destination for bakery
enthusiasts across India
Theobroma store Bangalore - Shop No-39, Shabari Arcade, M.P South B.B, 14th Main Rd,
opp. Max Showroom, HSR Layout, Bengaluru, Karnataka 560102
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1.4. Categories and Product Assortment
Chocoholic Cake
Blueberry Cheesecake
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Walnut Brownie
Cookie Brownie
Nutella Brownie
Banoffee High
Chocolate Cupcake
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Double Choco Chip Cookies
Pound Cake
Banana Cake
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Wheat Burger Buns
Theobroma expanded its online presence during the COVID-19 pandemic, launching its
online store to complement its physical outlets. They have partnered with PureTech digital
(in 2021) to drive rapid growth with the help of Puretech digital’s specialised services such as
SEP , market analysis. Theobroma's official website provides a user-friendly interface for
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browsing and purchasing products, allowing customers to easily order their preferred items.
Furthermore, Theobroma has collaborated with Puretech Digital to improve its digital
offerings, with the objective of establishing a direct connection with consumers and
enhancing its online presence. Theobroma has been able to expand its audience and offer a
more seamless shopping experience to its customers as a result of this strategic emphasis on
digital channels.
CHAPTER 2
INVENTORY ANALYSIS:
The Theobroma store in HSR layout is spread over an area of 700 square feet. This store
provides a compact dine-in space for customers who prefer to enjoy their pastries and
beverages on-site. The dine-in areas in particular store range from 15 to 30 seats, with some
cozy and minimalistic setup, focusing more on takeaway orders.
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Packaged Gift Items 3 months
FIFO dictates that the oldest inventory is sold first. This is crucial for managing perishable
goods For Ultra-Perishable and Perishable FIFO is paramount for these categories. Staff
would meticulously rotate stock, placing newer items at the back and older items at the front
of displays. Expiry dates are prominently displayed, and staff are trained to prioritize selling
older stock. Non-Perishable, while FIFO is still good practice, it's less critical for these items
due to their longer shelf life. However, it still helps maintain product freshness and prevents
items from becoming outdated. This technique also helps in accurate cost management, as
older inventory is recorded at its original purchase price, preventing inflated costs from
affecting profitability.
Theobroma follows the Periodic Inventory control system, This system involves physically
counting inventory at predetermined intervals. The frequency of these counts would vary
based on the product category. Which categories are Ultra-Perishable, Perishable,
Non-Perishable. Daily counts are essential to track these highly sensitive items . highly
sensitive products are called Ultra-Perishable products , which have very less self life like the
pastries .This allows for quick identification of items nearing expiration and minimizes waste.
For Perishable products the counts might be conducted every few days or weekly, depending
on the specific product. For Non-Perishable there are very Less frequent counts, perhaps
weekly or monthly, would suffice for these items. This system allows Theobroma staff to
focus on freshness, as periodic stocktaking helps identify expired items and adjust production
accordingly. Additionally, it minimizes the need for constant monitoring, reducing the
complexity of daily operations while still ensuring inventory is checked at regular intervals.
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2.3.3 Inventory Tracking technique - ( Point on sale system ) :
Theobroma utilizes a robust Point of Sale (POS) system to effectively manage and track its
inventory across multiple outlets. They have implemented the Torqus POS system, which
provides real-time sales data and a comprehensive inventory management solution. This
integration allows Theobroma to monitor sales and inventory levels across all their locations
seamlessly.
“Torqus made our daily operations a cake-walk. With Torqus, I am able to monitor the
sales and performance of all my outlets from anywhere” - Nihal Harchandrai, Head of
Finance and Strategic Initiatives at Theobroma.
Theobroma's daily ordering system with a 2-day lead time is a crucial part of their inventory
management strategy. It ensures that their retail stores receive fresh products regularly while
minimizing waste. Here's how it works: each day, the store assesses its current inventory
levels, considering both what's on display and what's in storage. They factor in recent sales
trends, upcoming promotions, and any special events that might affect demand. Based on this
assessment, they place an order with the central kitchen. This order isn't for immediate
delivery; instead, it's for delivery two days later. This 2-day lead time allows the central
kitchen sufficient time to prepare the items, package them, and organize delivery logistics.
This system is particularly important for Theobroma's perishable goods, as it ensures a steady
flow of fresh products to the stores, minimizing the risk of spoilage and maximizing customer
satisfaction.
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2.6. Inventory control measure :
● This is the foundation. Accurate forecasting drives everything else. Theobroma would
use historical sales data from their POS system, seasonal trends, promotions, and even
external factors (local events) to predict demand for each product.
● Knowing what to expect allows them to produce the right amount, minimizing waste
from overproduction of perishables and preventing stock outs of popular items.
This refers to the period for which demand is being forecast. Theobroma likely uses multiple
time horizons:
Matching the time horizon to the product's shelf life and the planning needs is critical for
efficient inventory management.
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2.6.4. Dead Stock:
● This refers to inventory that has become obsolete, spoiled, or is no longer sellable. For
Theobroma, this is a major concern due to the perishable nature of their products.
Theobroma aims to send back all the spoiled goods back to central kitchen.
● Dead stock represents a direct financial loss. Effective inventory control aims to
minimize dead stock through accurate demand forecasting, proper stock rotation
(FIFO), and timely markdowns or disposal of near-expiry items.
● This is the amount of a specific product that is ordered to replenish inventory. It's a
balance between ordering enough to meet demand and avoiding overstocking.
● Optimal reorder quantities minimize inventory holding costs (storage, spoilage) while
ensuring sufficient stock. It's often calculated using techniques like Economic Order
Quantity (EOQ) formulas, but these may need adjustments for perishable goods.
Daily Deliveries: Theobroma operates on a daily delivery cycle. This means that each retail
store receives a fresh stock of products every day, ensuring that they can replenish their
shelves and offer customers the freshest possible items. This daily rhythm is crucial for
managing ultra-perishable goods and maintaining consistent product availability.
In-House Delivery Network: Theobroma manages its logistics in-house, without relying on
any third-party delivery services. This gives them greater control over the entire process,
from production to delivery. By handling logistics themselves, they can ensure that their strict
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quality control standards are maintained, that delivery schedules are adhered to, and that their
temperature-controlled vehicles are properly managed. This direct control also allows them to
be more responsive to any unexpected issues or changes in demand.
Early Morning Deliveries: The 6 a.m. delivery time is strategic. By delivering early in the
morning, Theobroma ensures that retail stores receive their fresh stock before they open for
the day. This allows store staff to unpack and arrange the new products, ensuring that displays
are full and ready for customers when the doors open. Early morning deliveries also
minimize disruptions to store operations and allow staff to focus on customer service during
peak hours.
Theobroma operates with a 2-day lead time, which is a critical component of their inventory
and supply chain management. This means that from the moment a retail store places an
order with the central kitchen, it takes two days for those products to be delivered. This 2-day
window encompasses all the necessary steps, including order processing, production or
preparation of the baked goods, packaging, quality control checks, and finally, transportation
to the retail location. This lead time is factored into their daily ordering process, allowing
stores to anticipate their needs and ensure a consistent flow of fresh products. Managing this
2-day lead time effectively is essential for minimizing stockouts, reducing spoilage, and
maintaining the freshness and quality of Theobroma's delicate products.
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Fresh Product Focus:
In-House Logistics:
Each retail store is responsible for managing its own inventory levels, though guided by the
central kitchen's production planning and based on sales data. Stores use a combination of
POS systems, par levels, and visual checks to monitor stock and trigger replenishment orders.
The emphasis is on maintaining optimal stock levels to meet customer demand while
minimizing waste from spoilage.
While Theobroma might have a website or social media presence, their primary focus remains on their
physical retail stores. They may offer online ordering for in-store pickup or limited delivery options
through third-party aggregators in some locations, but their core distribution strategy is centered on
the in-store experience. This focus on physical retail allows them to control the quality and
presentation of their products, as well as the customer interaction.
Customer Experience:
Theobroma's distribution strategy is closely linked to their focus on customer experience. The
strategically located stores, fresh product availability, and emphasis on in-store service all contribute
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to creating a positive and consistent brand experience for customers. Theobroma's distribution model
supports their brand image as a provider of high-quality, freshly made baked goods.
A push supply chain strategy for Theobroma would center around anticipating customer
demand and proactively producing goods to meet those forecasts. This involves heavily
relying on historical sales data, seasonal trends, and promotional calendars to project which
products will be popular and in what quantities. Based on these forecasts, the central kitchen
would create production schedules, manufacturing items in advance and "pushing" them out
to the retail stores. This preemptive stocking aims to ensure shelves are always full and
customers can readily find what they want. While a push strategy can offer benefits like
economies of scale in production and readily available products, it also carries the risk of
overstocking, especially with Theobroma's perishable goods. Inaccurate forecasting can lead
to significant waste and financial losses. Therefore, for Theobroma, a pure push approach is
likely not the most effective. They probably utilize a hybrid model, perhaps employing a push
strategy for more shelf-stable items while relying more on a pull strategy (producing to order)
for highly perishable goods to minimize spoilage and maintain freshness. The key for
Theobroma is to strike a balance between anticipatory production and responsiveness to
actual demand, optimizing their supply chain to minimize waste and maximize customer
satisfaction.
2.10. Challenges:
Theobroma, like any business dealing with perishable goods and a complex supply chain,
faces a unique set of challenges in managing its inventory and supply system.
Challenge: Theobroma's products, especially ultra-perishable items like fresh cream cakes,
have a limited shelf life. Inaccurate demand forecasting or inefficient stock rotation can lead
to significant spoilage and financial losses.
Steps to Overcome:
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Enhanced Demand Forecasting: Implement more sophisticated forecasting models that
incorporate real-time sales data, weather patterns, local events, and even social media trends
to improve prediction accuracy.
Dynamic Pricing and Promotions: Implement systems that allow for dynamic pricing and
targeted promotions for near-expiry items to incentivize sales and reduce waste.
Strict FIFO (First-In, First-Out): Enforce strict FIFO practices in all stores, ensuring that
older products are always sold first. This requires well-trained staff and clear procedures.
Waste Tracking and Analysis: Implement systems to track and analyze waste. This data can
help identify patterns, improve forecasting, and optimize inventory management.
Challenge: Demand for Theobroma's products can fluctuate significantly due to seasonality,
holidays, special events, and even day-of-the-week variations. This makes it challenging to
maintain optimal stock levels.
Steps to Overcome:
Agile Production Planning: Implement flexible production schedules that can quickly adapt
to changes in demand. This may involve having backup plans and readily available resources.
Inventory Optimization: Use data analytics to identify optimal stock levels for each
product, considering demand variability and lead times.
Challenge: Delays in deliveries from the central kitchen, ingredient shortages, or unforeseen
events can disrupt the supply chain and lead to stockouts in retail stores.
Steps to Overcome:
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Contingency Planning: Develop contingency plans to address potential disruptions, such as
alternative delivery routes or backup suppliers.
Real-time Supply Chain Visibility: Implement technology that provides real-time visibility
into the supply chain, allowing for proactive identification and resolution of potential issues.
Conclusion:
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Annexure - Questionnaire :
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We follow first in first out technique for the the rotation of fresh stocks due to their low
shelf life.
10. Do you maintain safety stocks ?
Due to the low shelf life there would be no safety stocks kept except for the items with
long shelf life where the cookies are maintained at the level of 30 pieces.
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References :
https://order.theobroma.in/products/breads
Inresto. (2019, April 5). How Torqus Helped Theobroma Manage Their Backend
https://inresto.com/blog/how-torqus-helped-theobroma-manage-their-backend-o
perations-with-ease/?
BrandEquity, E. (2021, August 3). Theobroma partners with Puretech Digital to ramp
https://brandequity.economictimes.indiatimes.com/news/the-pitch-report/theobr
oma-partners-with-puretech-digital-to-ramp-up-digital-offerings/85003682
Punepulse, & Punepulse. (2024, November 8). Theobroma’s Journey: From One-Room
Trusted-Connected-Targeted.
https://www.mypunepulse.com/theobromas-journey-from-one-room-bakery-to-a
-potential-billion-dollar-exit/
Theobroma reaches milestone of 100 outlets in India – THE ECONOMIC INDIA. (2022,
August 24).
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https://economicindia.co.in/business/theobroma-reaches-milestone-of-100-outlets
-in-india/?
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