Supply chain = Logistics + purchase

Logistics:
Main functions and aspects 1. 2. 3. 4. 5. 6. 7. 8. 9. Finished goods planning order desk E-Care Inventory ERP- MOVEX Transporters management Receivables management Dealers management Supply management

Customer Order processing: 1. Dealers place the order to the sales team. 2. Sales team forwards it to CCL. 3. CCL carries out the order processing. Steps to be carried out while processing a order F14 for new customer order A. 1. Customer number: 60 Search Select the customer(Address comes automatically)(F4) 2. CO type B. 3. Warehouse 110- Ambattur 111-Imports 112-Coimbatore(ferroamb) 210-IGT 110- normal sales 110-high sea sales 120-free samples 120-free sample sales 130-sales return 140-adjustments 191-inter factory transactions 192-factory sales

310-Kalmeshwar 410-Khardha

4. Sales tax : vat, freight(4%(cst)),2%(local)) , e1 transactions, ED-12.5%. C. 5. Ln charge model : ED/Fr/CST 6. Address no. : (for delivery) [F4] 7. Delivery spec : Customer name (for reference) D. 8. CO number: refer P.O of dealer (34/12) 9. Date: 10: Our ref: 11. Your ref: CHQ open 12. Contact method: CBD- customer based discount DVD- dealer volume discount LPD- list price discount SPC- special price order(direct cust) VSD- volume based discount E. 13. Invoice no. : 01- excise pp132 02- traded pp132 F. 14. (price list) G. 15. (address sheet) H. 16. Warehouse: 17. Quantity: 18. Unit of measurement: pce I. 19. sales price: 20. net price 21. discount: 22. margin J. K. L. NOTE: 1. 2. 3. 4. (VERIFICATION of previous steps)

TRIGGER- (6) F15- (direct order lines) Delivery address quick view: (11) Post text(instructions) (F17)

STATUS 33: AVAILABLE, 22: NO MATERIAL , 44: PICK LIST

20: ORDER CLOSED, 77: IN VOICED APPROVALS 1) MARGIN<5% 2) RITES INSPECTION etc REPORTS 1) ORD38 STOCK MATERIAL 2) DESPATCH DETAILS etc

ORDER LOCKING 6) NO CHEQUE 7) PERMIT 8) OTHER ISSUES

FACTORY LOGISTICS
FORECASTING PRODUCTION PLANNING QA check (RM/WIP) FACTORY DELIVARY NOTE CHANGE OF LOCATION (Manu.FG) STOCK ORDER SYSTEM ALLOCATION PICKING LIST TRUCK PLANNING LOADING INVOICE DESPATCH (BTC and road permit)

NOTE: A manufacturer updates the stock in the system after every shift. Pick list : Stock zone/Item no./Order no./Line no./Location/Qty Rack capacity 3T. Racks are given alphanumeric codes and barcodes. Eg:G21. Invoice five copies: Original/Excise/Office excise/Duplicate/For file. After acknowledgement from customer Payment to transporter

PURCHASE
Two main aspects: 1. Procurement 2. Storage (Inventory) Based on forecasting and inventory, Purchase order proposals are generated automatically. Based on PO proposals and reorder level, procurement is done. Major raw materials being procured: 1. Powders and minerals (for electrode flux and saw flux) Eg: Rutile, Fe powder, Silicates, Magnesite 2. Coils mainly from TATA and SAIL Eg: Mild steel and SS. 3. Consumables (packing material) PO ref invoice certificate GRN QA inspection Raw material source RM stores: Stores all kinds of minerals and powders. Supplier MaterialTrucksWeighingQAGRN MovexUsable stock Put away label: 1. 2. 3. 4. 5. 6. 7. Item number: Lot number: Location Rec no.: Order number: Date: Supplier:

Cut wire stores: TATA/SAIL (5.5mm, 6mm) Sub contractors Drawn to required size. Instead of put away labels, BIN cards are used.

Vendors: o Identified by three sample process Development office o Once a vendor is finalized Trial orders Approval o With existing suppliers price negotiations are done based on market trend. o Contract reviews (6 months/1 yr) depending on the vendor

Transporter management:
Two modes of payment: 1. To be billed (consumables) 2. To pay (equipments) The focus is on implementing the Freight to pay system for consumables ASAP. An agreement is signed with the transporter which lists down a set of terms and conditions. Some of the points covered in that agreement are: Discipline Traffic rules License/RC etc POD Legal aspects FTL/Taurus/Non-FTL/Non-Taurus charges OD charges Door delivery charges LR/ Invoice copies Careful handling Covered trucks Transit insurance Proposed plan: i. ii. iii. The number of transporter contracts to be reduced to 15 from 41. The dealer will have to provide three transporters along with order of preference. Based on the availability of transport and order of preference material will be dispatched Major transporters: i. ii. iii. iv. V-trans ARC Inland Patel

Payment receivables and Cheque handling:

i. ii. iii. iv. v. vi. vii. viii. ix. Note: Customer aging report is generated from the MIS. From the aging report the outstanding value for each customer is obtained. The customer sends the open cheques via post. The details of the cheque are entered into the cheque register. Based on the outstanding values, the amount is entered in the cheque. In cases of large outstanding values, the amount is split into two or three cheques. The payment entered in the cheque is subsequently entered in the cheque register against the cheque number. In case of limited cheques, a number of invoices are combined into a single cheque. The cheque is then handed over to the accounts section. 1. A communication mail should be sent to the concerned customer before 2. The cheques are arranged based on the regions. North/ South/ East/ West/ Central.

depositing a cheque.

Planning:
i. ii. iii. iv. v. vi. ORD-38 report is generated from the MIS ORD-38 report is then converted into excel format and the unnecessary details are eliminated. The excel format consists details about the stock, age of the stock, quantity, value. The moving average is calculated is based on the order inflow and the quantity of the past six months. For runners, based on moving average forecasting is done. For repeaters and strangers, marketing team gives the forecast.

vii.

Based on the stock on hand and forecasting quantity, logistics team gives the production plan to manufacturing team.