INVENTORY MANAGEMENT
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PREFACE
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Acknowledgement
I wish to express my sincere thanks to all those individuals who guided me in a proper direction and providing essential information regarding report at their part. Without support and co-op o-ope erat ration of all, project would not have been completed I would like to express my sincere thanks to Ms. Yamini sinha (HR manager, PepsiCo, Jhagadia) who give us opportunity in their company to get training over their I would like to express my gratitude to all of HOD of the PepsiC PepsiCo o Holdi Holdings ngs pvt pvt Lt Ltd d who provid provides es me their their valuab valuable le infor informa matio tion n and and data data whic which h help helps s me in prep prepar ared ed proj projec ectt Report; I would like to give special thanks to Chetan Thakar for providing me production planning and shipping information.
- Purvesh Kansara
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Executive Summary PepsiCo is one of the multinational company having more than 400 brands in 190 countries. In India PepsiCo having 37 bottling Plants. At Jhagadia Pepsi has started its GRB plant in 1997, PET line in 2001, Aquafina in 2003. In PepsiCo I have visited Human Resource Department, Finance Department, Production Department, Quality Control, Marketing and Dispatch and Logistic Departments. The company’s Marketing Office at Ahmedabad.
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Background Of The Company PepsiCo Pvt.Ltd. is the world’s most powerful soft drink well reputed company in the FMCG market. It ranks in the most six companies in FMCG business, the history of are as under: • • •
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Founder – Mr. Caleb Bradham Year of foundation – 1890 It was originally founded as a cure for Dyspepsia & now, its name Pepsi soft drink. 1st plant setup in the year 1905 at America . In 1936 company earn $2 billion profit. Today its business is spread in more then 190 countries with 500 companies. In Gujarat Pepsi have 1 plant. BHARUCH ). ( JHAGADIA MEGA G.I.D.C. BHARUCH st 1 company of Pepsi in India was started at Jaipur (Raj.). In Jhagadia PepsiCo started first plant in 1997 with GRB (glass refilling bottle). In 2001 PET (poly ethylene tetracycline) was started. In 2003 AQUAFINA plant was started in Jhagadia. In 2010 SLICE plant was started in Jhagadia.
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VISION & MISSION STATEMENT VISION:•
PepsiCo vision is to be best Consumer Product Company in the world & wants to become the market leader in the market. Its main vision is satisfaction of supplier, customers, consumers, employees.
MISSION:•
PepsiCo’s mission is to deliver the best quality product in the market & try to achieve the maximum satisfaction.
MILESTONE SINCE INCEPTION • •
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In the year 1999 it wins Quality Assurance IQ award. In the year 2000 it wins award for 1 million hours without loss time accident. In the year 2000 it wins award for zero loss time accident. In the year 2000 it wins Pepsi Cola International Bronze Quality award. In the year 2001 it wins Pepsi Cola Beverages International Bronze Quality award. In the year 2001 it wins award for zero loss time accident.
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TYPES OF COMMUNICATION CHANNELS In PepsiCo company two types of channels are there :-
CHAIN COMMUNICATION: These communication exists between superior & subordinate according to there in an organizations. •
FREE FLOW FREE FLOW :In this communication each person can communicate with others freely in this network communication fast.
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PRESENT PRODUCT MIX Brand Name Pepsi Mirinda(orange ) Slice 7up Lehar Aquafina Mountain dew
200ml. 300ml. 600ml. 1liter •
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1.5liter 2liter •
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ORGANIZATION CULTURE :Organization culture consist of :• • • • • •
Open & transparent. Free forum & chain communication. Performance linked assessment. Mutual trust & respect. Non interference in internal matters. Team work.
POLICIES OF THE COMPANY Quality Policy
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We shall deliver the best product in the:Market place. Highest quality. Biggest testing.
Safety Policy We shall design, construct, maintain & safe operate our plant so that they are safe for: The people working in the company. The assets of the company. The environment in & around.
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COMPANY’S HEADS DETAILS Mr. Chetan Thakkar (Plant Manager) Mr. Yashpal Jajodia (Finance Manager) Mr. Nilesh Borisa (Account Executive) Ms. Yamini Sinha (HR Manager) Mr. Zubair Shaikh (HR Executive) (Quality Head) (Production Manager) (Production executive) (Shipping Head) (Shipping Executive)
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ORGANIZATIONAL STRUCTURE Mr.Chetan Thakar (Plant Manager)
Mr.Yashpal Jajodia (Finance Manager)
Mr.Nilesh Borisa (Account Executive)
Mr.Prakash Shah (Account Executive)
Ms.Yamini Sinha (HR Manager)
(Production Manager)
(Quality Control)
Mr.Zubair Saikh (HR Executive)
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ORGANIZATION LAYOUT
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PRODUCTION DEPARTMENT
Manufacture Manager
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Maintains Executive
Production Executive
Utility Associate
Production Associate
Production department has to plan the production schedule as per the sales. Implementation of the item. Achieve the production target. Maintain quality with goodwill. Safety of machine. Organize the training programme.
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PRODUCT SPECIFICATION •
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Pepsi Colour – Black Mirinda Colour – Orange Mountain Dew Colour – Off Green 7up Colour – Like Water (No Colour)
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Aquafina Colour – Water Slice Colour – Mango Lehar Colour – Like Water (No Colour)
RAW MATERIAL USED Water, Sugar, Preform, CO2 , Crown, Label.
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BOTTLE SPECIFICATION Particular
For 200 ml.
For 300 ml.
Height (mm) Fill Height (mm) Weight (gms) Base Diameter (mm)
209.5+1.20 247.7+1.20 57.2 57.2 312 390 54.5 59.6
PREFORM SPECIFICATION Particular
Specification
Weight (gms) Wall Th Thickness (m (mm) Length (mm)
25.5+0.3 3.5+0.25 107.4+1
Types of Material Handling Equipment Used
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Fork lift truck o 2 for shipping o 2 for production o 2 for sugar godown Chain conveyer (GRB LINE) Belt conveyer (PET LINE) Plastic chain conveyer (PET LINE) Air conveyer (PET LINE)
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Pumps (WATER TREATMENT) Roller conveyer (GRB & PET LINE)
BRIEF EXPLAINATION OF PRODUCTION PROCESS (GRB) GRB LINE (GLASS REFILLING BOTTLE)
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Prod Produc ucti tion on proce rocess ss st star arts ts from from unlo unload adin ing g of the the empt empty y bottles from the trucks. These bottles are taken by fork lift trucks which send in the plant line. Carats from fork lift & put on the roller conveyer. •
Uncaser Machine
Unca Uncaser ser Machi Machine ne keep keeps s the the bottl bottle e on the the autom automat atic ic conveyer belt from the carats. At once it pick up the 48 bottles from the 4 boxes on this belt 2 chips neck inspection points are set in order to remove remove any damage damage bottle bottle after inspection inspection are do going the further bottle.
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Bottle washer: (max-43000 bph) After bottle inspected bottles are goes to bottle washer.
Prejecting At this point the bottle is entering into the washer machine. At this time bottle is inwarded into bottles by the jobs. The dust washed in the prejecting 400 C tempe empera ratu ture re is maintaining the capacity. Detergent 1: In this this st sta age the the tank tank is fil filled led with with wash washer er & this this wate waterr cont contai ain n deter eterge gent nt.. At this this st stag age e miner iner dus ustt or oili oiline ness ss remove. Detergent 2: Bottles are passed through detergent-1 to detergent-2 tank. The capacity of detergent-2 tank is 21800 liters.
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Warm Water: The bottles are washed by the warm water at the temperature of 600-630. Here, bottles are sterilized & almost all microbes & bacteria’s are killed by warm water. Cold water: At this stage bottles are washed with cold water of 30 0-350 C. At this stage the temperature of the bottles is bought down to normal temperature.
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Refilling Bottles:
Empty bottles are refilled, which are passed through bottles. Bottles come from 4 inspection stages, the GRB capacity is 36000 bph. 80 valves in the filling bowl. The capacity of the machine is 36000 bottles per hour. The empty bottles are picked up by the filling bowl & filling automatically. Then bottles forwarded for sealing machine the bottles are sea sealed led with ith the the crow crown. n. After fter the the bottl ottles es are sea sealed led & crow crowne ned d they they pass pass thro throug ugh h prin printi ting ng machi achine ne.. Prin Printi ting ng machine print the manufacturing date, time, price after this steps the bottles are ready to final inspection.
In inspection identified: o Half fill o Full fill o Dirty bottles o Different crown 19
Different bottles The bottles are forwarded by the conveyer. o
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Caser Machine:
Case Caserr machi achine ne pi pick cked ed up 96 bott bottle les s & put into into the the carats then through conveyer belt; the carats are arranged into the pallets & then are arranged for fork lift truck into the finished goods godown.
GRB PLANT STRUCTURE
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PET LINE (POLY ETHYLENE THYLATE )
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PET line is a line of plastic bottle & its maximum capa capaci city ty for for 50 500m 0ml. l. bottl bottle e is 18 1800 000 0 bph, bph, for for 1. 1.5 5 lite liters rs its its capacity is 12000 bph, and for 2 liters it is 9000 bph. The entire machine on PET line is imported & is purchased from the reputed foreign companies like: Sidel (FRANCE) Linker (POLAND) Paramix (GERMANY) Krones (GERMANY)
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Blow Moludar:
In blow moludar machine performs are converted into PET PE T bott bottle les s capa capaci city ty of this this machi achine ne is 10 1040 400 0 bph. bph. This This machine is made by the Sidel (France Company) & price of this machine is 7 to 8 crore. Performs are brought in ‘HOPPER’ from to blow. Moludar machi machine ne through through convey conveyer. er. The comput computer er contro controlli lling ng the mach machine ine autom automati atica cally lly and and deci decide des. s. The The temp tempera eratur ture e of oven. For controlling the temperature, sensor cameras are installed which measure the temperature. Camera checking is done after every 50 performs. 8 models are set in blow in moludar & converted into exp expecte ected d shap hape. Bottle ttles s are send send uns nscr cram amb bler ler by air conveyer.
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Unscrambler:
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Main Main func functi tion on is stor store e the the bott bottle le from from ‘B ‘BLO LOW W MOLUDAR’. Bottles are stored because it has two reasons: It needs large large amount amount of PET bottles bottles continually continually;; PET bottles are stored in unscrambler machine. Blow moludar is a very high energy consumption machine, so electricity, cooling energy & continually and air is required the unscrambler machine arranges the bottle on conveyer. Air conveyer takes the bottles into filling hall. The bottles are washed for one time because some dust is their.
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Filler Bowl:
There are 54 valves in Pet filler bowl. Valves pick the bottle automatically. Syrup and CO2 are filled up autom automati atica call lly, y, stop stop auto automa matic tical ally ly and and after after.. This This crow crown n sealed done on the bottles. •
Warmer:
The bottle comes out from the filling halls which are very cold if these cold bottles are forwarded to the “labeler” then the label can not be fixed properly. The temperature of bottles is brought up to 200 to 250 C from 40 to 50 C. •
Printing Machine & Labeler:
This label is fixed in particular machine label. Machine has automatic capacity of 250 bph for 500 ml. & 200 bph for 1.5 liters & 150 bph for 2.0 liters. •
Case Packer Machine:
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Different sized pet bottles are packed into different size boxes. 96 valves-500ml 48 valves-1.5litres 27 valves-2litres •
Packaging Boxes:
The boxes are send forward through through conveyer conveyer & boxes are are goin going g towa toward rd boxes oxes seal sealin ing g st sta ation tion.. Here ere boxe boxes s are are seali sealing ng autom automati atica call lly y & arra arrang nged ed into into godo godown wn by the the lift lift truck operator.
SHIPPPING PROCESS
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AOP (Annual Operational Planning)
Target given to each Dealer
Order placed at plant level by all Dealers
Transportatio n Arrangement
Dispatched of Order
AOP (Annual Operational planning):
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Name suggest that operational planning would be done on annual annual based based and split split in to month monthly ly based based and based based on that that prod produc uctio tion n plan plannin ning g woul would d be done done,, and and targ target et are are given to each of all Dealers/Distributors, How it would be decided: On the the basis of las last year ear sale sales/ s/fo fore reca cast st data and plu lus s predefined predefined growth rate and it would be on all plant wise and it could be decided on its potentiality Who could be done: It could be decided at Head-office, Delhi Why it could be done:
Meaning:
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Inventory can be in the form of Raw-Material (RM), work in process (WIP) or as Finished-goods (FG)
Purpose of Inventory
Inventory is useful for the following purposes:
rder to engage in capacity planning and Predictability: In orde
schedu schedulin ling, g, you you need need to contro controll how much much raw-mat raw-materi erial, al, parts, parts, and and subassemblies you process at a given time. Inventory buffers what you process.
Fluctuations Fluctuations in demand: Inventory is assist in estimation of demand.
You don’t always know that how much stock you required at any given time, but you still need to satisfy your customer’s demand on time.
Unreliabi Unreliability lity of supply: supply: Inve Invent ntory ory kept kept when when ther theree is scar scarce ce of
resources or very few suppliers are available,
Price protection: Buying quantities of inventory at appropriate times
helps avoid the impact of cost inflation. When there is chances of price rising in future , better to purchase at presently at reasonable price and avoid price fluctuation cost
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Quantity discount: often bulk discounts are available if you buy in
large rather than small quantities
Lower ordering cost: if you buy a larger quantity of an item less
frequently, the ordering costs are less than buying smaller quantities over and over again.(The costs of holding the item for a longer period of time, however, will be greater)
Types of Inventory (stock):
Inventory basically falls into overall categories of raw materials, finished goods and work-in-process.
Raw Materials: Used to produce partial products or completed
goods. for e.g. sugar, concentrate, performs, labels, closures etc
current customer Finished Product : This is product ready for current
sales,
Work-inWork-in-proc process ess (WIP): (WIP): Item Itemss are are cons consid ider ered ed to be WI WIP P
during the time raw material is being converted into partial product.
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Other types of inventory:
Consumables: Light bulbs, Hand towels, computer and photocopying
paper, tape, envelops, envelops, cleaning materials, lubricants, lubricants, and so on.
Engineering (Service, repair, replacement and spare) items : These
are after-market items used to “keep things going”. As long as a machine or device of some type is being used and will need service in the future.
Buffer/Safety inventory: This type of inventory can serve various
purpose, such as:
Compensating for demand and supply uncertainties.
Holding it to “Decouple” and separate different parts of your
operation so that they can function independently from one another.
Transit Inventory: It could be argued that product moving within a
facili facility ty is transi transitt inven inventor tory. y. It may may also also define define as the the goods goods moving moving within distribution channel between you and outside to the facility user or provider.
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INVENTORY COST
It has include following cost like ordering, holding cost and stock-out cost
Ordering cost: It includes all cost incurred from placing order to receive
order and include
Price of goods
Salaries of purchase executives
Transportation cost
Damage cost
includ udee all all cost cost rela relate ted d from from rece receiv ivee orde orderr to Holding Holding cost: cost: It incl
dispatching products and has
Rent of factory
Security cost
Insurance cost
Obsolescence cost
Salaries of Store manager
Stock-out cost: It said to be cost when there is non availability of
material at a time of processing of finished goods which demanded by consumer ( loss of consumer)
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TYPES OF INVENTORY SYSTEMS
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Economic Order Quantity (EOQ) System:
It said to be place the order (in qty) at which ordering cost and carrying cost would be be minimum or said to be be equal,
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P Ordering Cost
C O S T
Holding Cost U
EOQ
R O
T No of orders 31
Ordering cost (OC): It incurred during placing order to
receive order like salaries of procurement, transportation cost, damage cost etc. It said to high when there are many orders placed and should be optimum so that frequency of order reduced cost. From above graph OP line it can be observed observed that as no of order order increased leads to increased increased in OC
Holding cost: It incur incurred red after after receiv receiving ing of mater material ialss to
getti getting ng into into proces processs like like rent rent of facto factory, ry, insura insurance nce,, secur security ity cost cost and salary of store manager, it said to be zero when there is no inventories in stores stores and incre increase ased d as store store mater material ial quanti quantity ty incre increase ased d so quant quantity ity should be optimum.
2. ABC Inventory control system:
Large no of firms have to maintain several types of inventories. It is not desirable to keep the same degree of control on all the items. The firm should pay maximum attention to those items whose value is the highest.
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The firm should, therefore, classify inventories to identify which items shou should ld rece receiv ivee the the most most effo effort rtss in cont contro roll llin ing. g. The The firm firm shou should ld be sele select ctiv ivee in its its appr approa oach ch to cont contro roll inve invest stme ment nt in vari variou ouss type typess of inventorie inventories. s. This analytical analytical approach approach is called called the ABC analysis and tends to measure the significance of each item of inventories inventories in terms of its value.
high-value items items and would would be under the ‘A items’ represents the high-value
tightest control
represent entss relat relative ively ly least least value value and and would would be under under ‘C items’ repres
simple control
‘B items’ falls in between above these two categories and require
reasonable attention of management
The following steps are involved in implementing the ABC analysis:
Class Classify ify the items items of invent inventorie ories, s, determ determini ining ng the the expec expected ted use in
units and the price per unit for each item
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Determining the total value of each item by multiplying expected
units by its unit price
Rank the items in accordance with the total value, giving first rank to
the item with highest total value and so on
Compute the ratios (percentage) of number of units of each items to
total units of all items and the ratio of total value of each item to total value of all items.
Comb Combin inee item itemss on the the basi basiss of thei theirr rela relati tive ve valu valuee to form form thes thesee
categories-A,B and C
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Item
Units
%
Cumul
Unit
Total
%
Cumul
Of
ative
Price
Cost
of
ative
%
(Rs) 30.40
1
10,000
Total 10
2
5,000
5
3
16,000
16
4
14,000
14
5
30,000
30
6
15,000
15
7
10,000
10
15 45
100
(Rs) Total 3,04,00 38.00
51.20
0 32.00
5.50
2,56,00 11.00
5.14
0
9.00
1.70
88,000
6.38
1.50
72,000
2.81
0.65
51,000
0.81
% 70
90
100
22,500 Total
1,00,000
100
6,500 8,00,00 0
The tabular and graphs presentation indicate that
‘ Item A’ forms a minimum proportion, 15 percentage of total units of
all items, but represents the highest value, 70 percentage 35
‘Item C’ represents 55 percentage of total units and only 10 percent
of total value
‘Item B’ occupies middle place and contains 30 percent of total units
and represents 20 percent value of total value
Items A and B jointly represents 45 percent of total units and 90 percent of the inve investm stment ent.. More More than than half half of the total total units units are item item C, repre represen sents ts merely 10 percent of total investment
100 80 C 60 O 40 S T 20
Item A
10
Item B
Item C
30 50 70 Percentage of units
90 100
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(3) JUST IN TIME (JIT) SYSTEM:
Japanese firms popularized the just-in-time just-in-time (JIT) system in the world . In a JIT system system mater material ial or the the manufa manufactu ctured red compon component entss and parts arrives to the manufacturing sited or stores just few hours before they are put to use. The delivery of material is synchronized with the manufacturing cycle and speed. JIT system eliminates the necessity of carryi carrying ng large large inven inventor tories ies,, and and thus, thus, saves saves carryi carrying ng and and other other relate related d costs to the manufacturer. The system requires perfect understanding and coordination between the manufacturer and suppliers in the timing of del deliver ivery y and quan uantity ity of the materi terial al.. Poor qual uality materi teriaal or comp compon onen ents ts coul could d halt halt the the prod produc ucti tion on.. The The JIT JIT inve invent ntor ory y syst system em complements the total quality management (TQM). The success of the system system depend dependss on how well a compa company ny manag manages es its suppl supplier iers. s. The The system puts tremendous pressure on suppliers. They will have to develop adeq adequa uate te syst system em and and proc proced edure uress to sati satisf sfac acto tory ry meet meet the the need needss of manufactures.
(4) OUT-SOURCING: OUT-SOURCING:
A few years ago there was a tendency on the parts of many companies to manufacture all components in-house. Now more and more companies
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are adopting adopting the practice practice out-sourcin out-sourcing. g. Out-sourcing is a system of buying parts and components from outside rather than manufacturing them internally. Many companies develop a single source of supply.
Introduction to Inventory Management •
Inventory constitutes the most significant part of current assets of a large majority of companies in India.
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The term inventory inventory refers refers to the stockpil stockpilee of the products products of the firm is offering for sale and the components that make up the product.
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The The vari variou ouss firm firmss in whic which h inve invent ntor orie iess exis existt in manu manufa fact ctur urin ing g companies are :
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Raw-materials inventories.
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Work-in-process inventories.
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Finish goods inventories.
Invent Inventory ory contro controll refers refers to the the proce process ss where whereby by the inves investme tment nt in materials and parts carried in stock is regulated within predetermined limits limits,, set in accor accordan dance ce with with the inven inventor tory y polic policy y establ establish ished ed by management.
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The production manager favors relatively higher levels of inventory so that production production process process runs smoothly. smoothly. The marketing marketing manager manager
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prefers to have reserves of finished goods so that availability of product is ensured even even if demand for the product product keeps fluctuating. •
The The financ financee manage managerr justif justify y limit limited ed stock stock level levelss becau because se of them, them, inventory blocks money which doesn’t earn interest.
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Raw materials are those basic input materials that are converted into finish finished ed produ product ct throu through gh manuf manufact acturi uring ng proces process. s. Raw Raw materia materials ls inventories are those raw materials inventory units which have been purchased and stored for future. future.
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Work-in-process represents products that need more work before they become finished product product products for sale.
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Introduction to Inventory Management in PepsiCo India Holdings (P) Ltd. A study at PepsiCo India Holdings (P) Ltd. was carried out taking into consideration the concept f total material control, which significant that efficiency of any organization is upon having the right quality, right place in right quantity at right time and at right place in following broad areas: 1. Purc Purcha hase se con contr trol ol.. 2. Stor Storag agee con contr trol ol.. 3. Wareho Warehouse use Accoun Accountin ting. g.
Purchase Control: •
Purc Purcha hasi sing ng is one of the basi basicc funct unctio ion ns of invento entory ry management and forms a major part of it. It needs considerable expert expertise ise not not only only negoti negotiati ating ng but also also in the the techni technique quess of competition and studying in large economic trends in respect of mate materia rials ls to be purc purcha hase sed d in larg largee quan quanti tity ty to incr increa ease se the the profit.
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Objective: o
To maintain continuity of production.
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To contribute toward higher productivity. productivity.
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To buy for the best ultimate value not necessary at the lowest initial price.
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To contribute towards standardization, variety reduction and value analysis programs.
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Functions:
Purch Purchase ase time: time:-Th -Thee purch purchase ase time time indic indicate atess the the lead lead time i.e. time taken to physically receive the material from the date of its indent. To find out the lead time five cases diff differ eren entt item itemss have have been been stud studie ied d rand random omly ly,, and and analyzed its fact which indicates that by following the existing procedure, the administrative lead is very long i.e. 5 to 7 months, while suppliers lead time about 2 to 3 months.
Purchase Purchase quality quality & quantity: quantity:-- It has been observed observed that the quantity of material is being purchase considering 6 to 12 months months consum consumpti ption on that that means means no econom economic ic orde orderr quan quanti tity ty has has been been fixe fixed d for for diff differe erent nt type typess of material.
Purc urchase Pric rice:e:- The price rice of each ach item tem is bein being g compa compared red with with suppl supplier ier’s ’s quotat quotation ionss consid considerin ering g the the
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quality of material to be supplied. Also the price and terms are considered.
Store Control:
The The cont contro roll of mate materia rials ls whil whilee in stor storag agee is affe affect cted ed through what is known as the perpetual inventory. Thus main functions of the perpetual inventory system have been studied which are: •
Receipt and issue system
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Maintenance of store records.
Warehouse Accounting:
The procedure comes in to operation immediately on receipt of dispatched documents or dispatched intimation in the stores and covers on the activities, i.e. clearness, delivery, inspection, stock charging and preservation, issue and return of materials by the consumer and ends after striking out of balance from the stock card and delivery of documents to the account department. •
Stores ledger
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Physical stock verification.
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An insight in the study
I have selected selected the topic “INVENTORY “INVENTORY MANAGEM MANAGEMENT” ENT” as my special topic of finance department on which I have prepared a mini project including raw inventories, work-in-process inventories, and finished goods inventories. The subject is related with the analysis of the inventory management for the investment of inventories in the PepsiCo India holdings (P) Ltd.
Objective of the study:
The report includes following main objectives, are as under: •
To find out the operation cycle.
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To study of the various inventories ratio.
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To analysis of inventory management techniques used in the PepsiCo India Holdings (P) Ltd.
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To study and analysis the inventory management system and control practices at PepsiCo India Holdings (P) Ltd.
The objectives of the report are concerned with an Ideal Inventory Manag Manageme ement. nt. An ideal ideal inven inventor tory y manage managemen mentt give give the minim minimum um storage of the different types of the inventories and maximum sales of the product of the company that’s why it increase in the wealth of the company.
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