CHAPTER-4 ar PRESENTATION AND ANALYSIS OF DATA el Introduction of Sample Cement Industries Evaluation of Inventory Management Performance Inventory Turnover Ratio Es t Days of Inventory Holding (DIH) Size of Inventory Linking Inventory Management to Profitability Statistical Analysis Regression Analysis Analysis of Primary Data 129 130 ar el Es t CHAPTER-4 PRESENTATION AND ANALYSIS OF DATA Inventory is one of the key determinants of the productivity of cement industry. The productivity of the cement industry is judged by its capacity ar utilization and economical use of major inputs such as limestone, coal, gypsum, stores and spares, and power consumption per tonne of cement production. Inventory management plays an important role in the cement industry both in production of new assets and operational maintenance of el existing assets. Therefore, the continuous availability of inventory is a prime requirement for the uninterrupted working and better capacity utilization. Against this backdrop, a modest attempt has been made to analyze the size Es t and relationship of inventory with various items in the balance sheet of the selected cement manufacturing companies in Nepal, during the Nine years period commencing from 2001-02 to 2009-10. So this chapter deals with the presentation and analysis of data following the research methodology. In the course of analysis, data gathered from various sources have been inserted in the tabular form according to their homogeneous nature and they are analyzed using financial and statistical tools. Finally the result obtained from the analysis has been interpreted on the basis of some conventional standards. 4.1 Introduction of Sample Cement Industries 4.1.1. Udayapur Cement Industry Limited It is the largest cement industry in Nepal which was established in 31 Jestha, 2044 B.S. (14 June 1987 AD) at Jaljale, Triyuga Municipality ward No. 11 of Udayapur district although, it started it’s commercial production from Poush 131 2049 B.S. (November 1992 AD). It was incorporated under the Company Act 2021 (now Company Act 2053) with the share investment of Nepal government and Overseas Economic Co-operation Fund (OECF)’s assistance to meet the foreign currency requirement. OECF has contributed Japanese Yen 18770 million and Nepal government has contributed Rs. 450 million to its total paid up equity capital. The main objective of establishing this industry is to make substantial contribution to the process of development of Nepal by ar producing highest quality of cement through the maximum mobilization of raw materials and manpower available in the country. The specific objectives of the industry are as follows. 1. To produce the basic import substantial and export quality cement based el on available resources in the country. 2. To manage for an extensive market 3. To enable the country become self reliant by supplying to the national Es t requirements. 4. To enhance industrial and economic development. 5. To provide employment opportunities. The capital structure of the industry is as follows: Table No. 4.1 Capital Structure of Udayapur Cement Industry Sources Amount (Rs. in ‘000’) Equity share 4437512 Preference share 3204300 Government debt 2556200 The industry has production capacity of 840 metric tonne of clinker per day and subsequently 277200 metric tonne of cement per annum. Despite its 132 rated annual production capacity the industry, due to various reasons, is not being able to yield its full-fledged production from the very beginning of its establishment. The average capacity utilization during the 15 years period is about 45 percent means it produces about 125,000 metric tonne per year and the industry alone meet about 15 percent of the total demand of the nation. (The estimated annual requirement of cement in the country is 2.5 million to per year.)1 Until 2009 (2065-66 BS) this industry has made the cash payment ar of 1500 million rupees to Nepal Government as capital and interest. To operate in its full capacity, the industry requires the following quantity of raw material and fuels. Table No. 4.2 el Annual Quantities of Raw Materials and Fuel of Udayapur Cement Industry Particular Utilities Units Remark 1 Limestone 330000 Metric ton Per year 2 Clay 57000-82500 Metric ton Per year 3 Sand 21000 Metric ton Per year 4 Iron ore 4000 Metric ton Per year 5 Gypsum 10500 Metric ton Per year 6 Coal 50000 Metric ton Per year 7 Jute bags 5540000 Piece Per year 8 Furnace oil 12000 Kilo liter For contingent use 9 Electricity 10000 Kilo watt Per year (Approx.) 10 Diesel 900 Kiloliter Per year (Approx.) Es t S.N. Source: Udayapur Cement Industry Ltd.- At A glance. Among the above mention raw materials the major raw material for cement production i.e. limestone is acquired from Sindali limestone quarry district. Similarly Clay and Sand are available in the local area. But the industry has to 133 import coal, gypsum, iron ore and furnace oil from other countries, particularly from India. The industry produces high quality “Gainda” trade mark cement that has received certificate of quality standard (NS mark) from Nepal government. Quick setting, highly durable and triturated characters are other features of the cement produced by this industry. ar 4.1.2. Hetauda Cement Industry Limited The Hetauda cement industry ltd. is situated at Lamsure of Hetauda municipality, Makawanpur district of Narayani zone about 80 Kilometers from the capital city of Kathmandu. It was established in 2033 B.S. (1976 A.D) under el the company act 2021 (now company act 2053). The industry covers about 149 bighas (249.9 acres) of area. Basically, an import substitution industry totally dependent on locally available raw materials-lime stone- the HCIL was Es t established to make the country self reliant on such an important construction material as cement and there by facilitate the acceleration of the tempo of the all around development of the country. The industry has generated direct employment opportunities for about 1100 persons and indirectly benefiting about 6000 persons.2 It has an installed capacity of producing 800 metric tonne of cement or 16000 jute bags of cement a day i.e. 260000 metric tonne or 5.2 million jute bags of cement per year. In this way the industry is helping to meet substantial percentage of the present cement requirement of the country. In HCIL marketing of Cement all over the country was done through three Government's agency namely National Trading Ltd., Sajha Bhandar and Tara Gaon Bikash Samiti and 62 private dealers. At present about 270 dealers are engaged in sales & distribution of cement. 134 By way of sales tax from the very year of the start of the commercial production of cement and by way of excise duty after three years of the production the HCIL is contributing substantially to the national exchequer. The average capacity utilization of this cement industry is about 45% during the last 20 years period. It was financed with the share investment of Nepal government and the loan assistance of the Asian Development Bank (ADB). The industry also used credit ar from national and international commercial banks. Of the total cost of 1389 million rupees, ADB has provided a credit of 732 million rupees while Nepal government has invested 206 million rupees in shares. Of the rest 243 million rupees have been received as short term loan from Nepal bank limited and el 208 million rupees from other international commercial banks. Table No. 4.3 Annual Quantity of Raw Materials and Fuels Es t of Hetauda Cement Industry Ltd. Materials Quantities (metric tons) Limestone 396000 Clay 20000 Coal 50000 Gypsum 12000 Iron ores 4000 Jute bags 5.2 million pieces The major raw material limestone is acquired from the Bhaise where a deposit of about 10 million tons of limestone is estimated. Similarly about 10 million tonne of high grade limestone is also estimated at Okhre danda some 8 km from Bhaise. 135 4.2 Evaluation of Inventory Management Performance Inventory management is a part of overall management process of an organization. It is the formal management of the organization in term of minimizing investment on inventories and maximizing the organization’s overall earnings. Profit is the major element of each and every business endeavor for its existence, survival and to fulfill the organizational expectations. To achieve the profit objective one of the major task of the ar organization is to manage inventories efficiently. An efficient inventory management system is dependent upon the development of appropriate planning and control techniques and proper implementation of those techniques. Inventory control primarily concerns with the administration of el the established policies and procedures. Thus, in inventory control involves maintenance of inventory records for the physical and accounting control of the inventories. Inventory management function involves the development Es t and administration of policies, systems and procedures which will minimize total cost relative to inventory decisions and related functions such as customer service requirements, production scheduling, purchasing, traffic etc.3 4.2.1 Structure of Inventories in the Selected Cement Industries of Nepal The composition of inventory is mostly affected by the nature and type of business. In the trading concern the major portion of total inventory would consist finished goods and they would have little investment in the raw materials, work-in- process and spare parts but a manufacturing organization has to invest in each component of inventory for the smooth and uninterrupted production and sale. A manufacturing firm generally holds four types of inventories viz., raw materials work-in-process, finished goods and spare parts.4 The share of each component in the total inventory varies from 136 industry to industry. Generally in public enterprises like cement industry there is high investment in store and spare parts in comparison of raw materials. The structure of inventory in the two- cement industries of Nepal divided into four categories. (i) Raw material- It includes Limestone, Coal, Fuel, Iron ore, Gypsum and bags. (ii) Semi finished goods- It includes clinker and raw meal. goods. ar (iii) Finished goods- cement produced by the industry denotes finished (iv) Spare parts and store- Generally, store and spare parts denotes loose tools and spare parts of machine but in the cement industry spare part el include general store in mine and plant, mechanical and electrical store in mine and plant, explosive, Japanese lubricant and fuel store in plant and mine. Es t 4.2.2 Structure of Inventory The size of investment in inventories in the two- public cement industries are different due to their production capacity and inventory management policies. In public enterprise like cement industry, there is high investment in stores and spare in comparison of other type of inventories. In the cement industries raw materials includes coal, gypsum, iron ore and lime stone and in-process goods consists crossed limestone, raw mill and Clinker. Therefore, in the context of cement industry raw material and work-in-process are basically same because in the production of cement inputs should pass through different stages of production. The composition of various type of inventory in the public cement industries of Nepal is presented below. 137 Table No. 4.4 Composition of Inventory Investment in UCIL (Rs. in millions) Fiscal Year Types of Inventory Raw materials Work-in Process % Amount % Amount % Spare Parts & Stores Amount Total % 26.98 7.1 35.8 9.42 26.22 6.9 292 76.84 380 2002-03 33.86 8.54 42.52 10.72 24.3 6.13 295.75 74.6 396.5 2003-04 58.29 12.61 58.68 12.7 55.8 12.07 290.2 62.78 462.2 2004-05 93.32 18.92 50.88 10.31 43.4 8.8 305.8 62 493.2 2005-06 56.3 11.78 53.8 11.25 41.2 8.62 326.59 68.38 477.89 Es t el 2001-02 ar Amount Finished Goods 2006-07 77.74 14.66 61.2 11.54 52 9.8 339.7 64.04 530.4 2007-08 89.66 14.03 79.1 12.38 85.24 13.34 389.51 60.97 638.84 2008-09 150.3 19.94 86.72 11.50 115.6 15.33 412.75 54.75 753.77 2009-10 155.8 19.07 97.4 11.93 112.6 13.78 450.79 55.20 816.59 Mean ( X ) 82.47 62.9 61.81 344.78 S.D(σ) 43.31 18.83 31.63 49.35 C.V. 0.53 0.30 0.51 0.14 138 139 ar el Es t From the above table No. 4.4 and chart No. 1 it is clear that in the UCIL the size of three types of inventories (raw material, WIP & finished goods) were in raising trend throughout the period of study except in year 2005-06. The materials consumption in the industry is erratic. This indicates that there is no sound purchasing policy in the organization the figure of raw material inventory was Rs. 26.98 million in 2001-02, which increase every year and became Rs. 155.8 million in year 2009-10 except in year 2005-06 where the ar value of raw materials was Rs. 56.30. The average size of raw material was Rs. 82.47 Million, standard deviation was 43.31 and C.V. was 53%. The rate of increase in the size of raw material according to trend line equation was Rs. 27 million which is very high. The el percentage of raw material inventory to total inventory was also in raising trend except in year 2005-06. The stochastic trend of material figures during the study period indicate that the industry was not using modern Es t procurement techniques like properly maintained stock level, practice of safety stock and economic order quantity. Similarly, the size of Work-In Process (WIP) inventory and percentage of WIP to total inventory were in increasing trend throughout the study period. It was Rs. 35.8 million in year 2001-02 and at the end of study period (2009-10) became Rs. 97.4 million. The average value of work-in- process inventory was Rs. 62.9 million, the percentage of variability was 18.33% and co-efficient of variation was 30%. Cement represents finished goods in this industry, as there is high demand of Nepali cement product in the Nepalese cement market therefore, the proportion of finished goods inventory in the total inventory is comparatively small but the trend of finished goods inventory during study period was increasing. The figure of finished goods inventory was Rs. 26.22 million in 2001-02 and became Rs. 112.6 million in 2009-10. The percentage of finished 140 goods inventory to total inventory was also in increasing trend which was 6.9% in 2001-02 and 15.33 in 2008-09. The stores and spares generally represent spares parts of machine in average manufacturing industries but in the cement industry it includes general store in mine and plant, mechanical and electrical store in mine and plant, explosive, Japanese lubricant and fuel store in plant and mine is very high. ar therefore, the value of stores and spares inventory in the cement industry Almost all spare parts brought from third country so their composition and stocking policies are different from that of raw materials and consumable el finished goods. Share of stores and spares parts to total inventory was very high in the beginning of the study period i.e. Rs. 292 million out of Rs. 380 million or 76.84%. It was in decreasing trend thus, at the end of study period it became Rs. 450.79 million out of Rs. 816.59 million or nearly 55%. The Es t average size of spare parts and stores was 344.78 and C.V. was 14%. The rate of decrease in the size of spare and stores was Rs. 8.6 million per year according to regression line equation. 141 Table No. 4.5 Size and Composition of Inventory Investment in HCIL ( Rs. in millions) Fiscal Year Types of Inventory Raw materials Work-in Finished Goods Spare Parts & Process % Amount Stores % Amount % 2001-02 42.66 18.03 29.54 2002-03 52.59 20.89 24.56 2003-04 76.57 30.10 27.28 10.72 12.59 4.95 2004-05 64.52 26.92 15.59 6.5 % 12.48 31.42 13.28 132.94 56.19 236.56 9.75 11.2 146.34 58.13 251.72 138.07 54.28 254.33 11.22 132.65 55.34 239.66 12.62 9.07 3.94 134.95 58.69 229.93 el 28.2 Es t 26.89 2005-06 56.8 24.7 2006-07 87.53 33.33 31.18 11.87 10.41 3.96 133.45 50.82 262.56 2007-08 100 35.27 30.78 10.85 10.7 3.77 141.96 50.08 283.45 2008-09 111.93 32.36 61.97 17.92 23.09 6.67 148.81 43.03 345.79 2009-10 136.27 36.01 73.15 19.33 18.23 4.81 150.7 39.83 378.35 29.04 Amount ar Amount Total 80.92 35.89 18.94 139.92 S.D(σ) 29.0 17.69 8.17 6.76 C.V. 0.36 0.49 0.43 0.048 Mean ( X ) 142 143 ar el Es t The size of various types of inventories in the HCIL during the study period was not found in the homogeneous trend. The size of raw material was showing peak and troughs. It was Rs. 42.66 million in 2001-02 which kept increasing, for the following two year then decreased for the next two years, finally increasing back again for the last four years i.e. it was in increasing trend. The figure of raw material inventory was Rs. 52.59 million in 2002-03, Rs. 76.57 million in year 2003-04 then showing decreasing trend for the year ar 2004-05 and 2005-06 with value of Rs. 64.52 million and Rs. 56.8 million and then finally for the last three years it was in increasing trend so it became Rs. 150.3 million in year 2008-09 but at the end of study period it decreases to Rs. 136 million. el The average size of raw material was Rs. 80.92 million, standard deviation was 29 and the fluctuation of 29% in the raw material was seen during the study period, which shown by the C.V. of the industry. The rate of increase in the Es t size of raw material according to trend line equation was Rs. 12 million per year which seems reasonable in comparison of total inventory holding. The percentage of raw material inventory to total inventory was also in rising trend except in year 2004-05 and 2005-06. Similarly, the size of work-in process inventory and percentage of WIP to total inventory were in increasing trend throughout the study period except in year 2004-05. It was Rs. 29.24 million in year 2001-02 and at the end of study period (2009-10) became Rs. 73.15 million. The average value of work-inprocess inventory was Rs. 35.85 million, the percentage of variability was 17.69 and co-efficient of variation was 49%. The trend of finished goods inventory in the HCIL was stochastic i. e. in year 2001-02 Rs. 31.42 million then in 2002-03 and 2003-04 decrease to Rs. 28.2 million and Rs. 12.59 respectively. After then in the year 2004-05 it again increase to Rs. 26.89 million. Then again in 2005-06 it decrease to Rs. 9.07 million and for the rest 144 two years it was in the minor increasing trend but in the year 2008-09 it increased dramatically and became Rs. 23.09 million. In the final year the amount of finished goods inventory decreased to Rs. 18.23 million. The percentage of finished goods inventory to total inventory was also in stochastic trend indicating mostly decreasing patterns. Percentage of stores and spare parts to total inventory in HCIL was comparatively high in the beginning of the study period i. e. Rs. 132.94 ar million out of Rs. 236.56 million or 56.10%. It was in decreasing trend thus, at the end of study period it became Rs. 150.7 million out of Rs. 378.35 million or about 40%. The average size of spare parts and stores was Rs. 139 million, standard deviation was 6.76 and CV was 4.8%. The rate of el decrease in the size of spares and stores was Rs. 8.6 million per year according to regression line equation. The composition of various components of inventory is determined Es t according to the nature and type of organization therefore it varies industry to industry. Hence, balance has to be maintained to control the total investment in inventories but accumulation of high percentage of spare parts in the total inventories is a common problem in the cement industries. Stores and spare parts in Nepalese cement industry are imported from and outside of India which takes long time to procure and their cost is also very high. Due to these reasons the percentage of stores and spares is relatively high in comparison of other type of inventory. Inadequacy of stores and spares might interrupt production process and excessive holding involve heavy financial and administrative burdens on the firm which ultimately decreases profit. 145 4.3 Inventory Turnover Ratio After the analysis of distribution of the inventories amongst the different components the next important aspect of inventory management is to seek answer about the utilization of the inventories investment. The general measure of assessing the utilization of the inventory investment is to compute inventory turnover because the review of the behavior of turnover ratios over ar a period of time can indicate the utilization of the inventory.5 The inventory turnover ratio measures a company’s efficiency in managing its investment in inventory. The ratio shows the number of times the inventory is turned over during the year. It indicates how quickly inventory is sold. Higher el the ratio, the more efficiently an enterprise has managed inventory, other things remaining the same.6 In other words inventory turnover ratio measures the rate of speed with which inventories move through and out of the enterprise. Inventory turnover establishes a relationship between the sales Es t during a given period and the average amount of inventory outstanding during the same period and also establishes a relationship between average inventories to sales. Inventory turnover indicates the speed with which assets are being converted into sales. Turnover of inventory directly affect the profitability of the firm. The higher is the turnover, the greater is the profitability of the firm and vice versa. A higher turnover also indicates that the firm has conducted more business with less amount of inventory. Inventory turnover acts as an indicator of the liquidity of inventory.7 Ordinarily, the higher the inventory turnover, the smaller the amount of working capital tied-up in the inventory and more current stock of merchandise, leading larger the amount of profit. Conversely a very high level of inventory turnover may be the result of very low level of inventory which may cause frequent stock out problem, even 146 though high inventory turnover ratio is always desirable in normal condition.8 There are two approaches of analyzing inventory turnover. 4.3.1 Cost of Goods Sold to Inventory Ratio The inventory to sales ratio measures the percentage of inventories the company currently has on hand to support the current amount of sales. The ratio is computed by dividing the period's cost of goods sold by the average ar inventory balance. The denominator, average inventory, is determined by adding beginning and ending inventory and dividing by two. Preferably, the average inventory value should be calculated by summing the monthly figures during the year and divide by twelve. If monthly data are not available one can el add the beginning and ending figures and divide by two. Both methods adjust for growth but not for seasonal effects.9 In this study due to the lack of monthly data of the inventory annual inventories data is taken Es t for the computation of inventory turnover. A single figure of inventory turnover is meaningless. It becomes meaningful only when it is compared with the enterprise’s past inventory turnover therefore, to find out the inventory management performance of the public cement industries of Nepal inventory turnover for the nine consecutive years are presented below. 147 Table No. 4.6 Inventory Turnover Ratio on the Basis of Cost of Goods Sold (Rs. in millions) Year HCIL UCIL Inventory Turnover CGS Inventory Turnover 2001-02 372.5 236.56 1.57 350.4 380 0.922 2002-03 388.54 251.71 1.544 365.58 396.52 0.921 2003-04 507.61 254.52 2004-05 471.54 239.65 2005-06 502.04 230 2006-07 483.83 262.58 1.843 2007-08 714.7 283.42 2008-09 658.52 345.79 ar CGS 395.77 462.15 0.856 1.968 405.17 493.22 0.822 2.183 509.68 477.6 1.067 422.74 530.4 0.797 2.522 432.57 638.85 0.677 1.91 398.06 753.8 0.528 406.21 816.59 0.497 Es t el 1.995 2009-10 Mean Deviation CV 710.63 378.35 1.88 1.93 0.79 0.2801 0.30 0.15 0.57 148 149 ar el Es t From the table above it is observed that the inventory turnover ratios of both cement industries were very low. The inventory turnover ratios of HCIL during the study period were better than that of UCIL but turnover ratios of both industries were not satisfactory and were far from the benchmark of inventory turnover ratio. The inventory turnover ratio of HCIL varied from 1.544 times per year to 2.522 times per year. In year 2001-02 the ratio was 1.57 times per year, meaning that the amount of money invested in ar inventories were turn into cash after 232.48 days. The inventory turnover ratios of UCIL throughout the study period were very low, indicating-except in year 2005-06 no turnover of inventory even one time in a year. In this industry the highest turnover ratio during the study period was 1.067 in year 2005-06 el and lowest 0.49 in year 2009-10. The mean value of inventory turnover ratio was 1.93 times and .79 times in the HCIL and UCIL respectively. The standard deviation of HCIL’s inventory turnover was 0.28 and UCIL’s inventory turnover Es t was 0.30 and C.V. were 15% and 57% respectively. The inventory turnover ratio of both industries is very low which indicate inventories are kept in stock for a long period of time; as a result unnecessarily funds are ties up in them. The direct effect of low inventory turnover will be on profit, therefore the net profit of the industry throughout the study period were very poor. The main reason of being inventory turnover ratio very low lay on high proportion of stores and spares parts inventory in the total inventory in the both industry. Large amount of funds was blocked in the stores and spares part that simultaneously affected in the raw material, as a result inventory turn over ratio became low. 4.3.2 Sales to Inventory Ratio A problem arises in calculating and analyzing inventory turn over ratio. Sales are stated at market prices, so if inventories are carried at cost, as they generally are, the calculated turnover overstates the true turnover ratio. 150 Therefore, it would be more appropriate to use cost of goods sold in place of sales in the formula’s numerator. However, established compilers of financial ratio statistics such as Dun and Bradstreet use the ratio of sales to inventory carried at cost. To develop a figure that can be compared with those published by Dun and Bradstreet and similar organization, it is necessary to measure inventory turnover with sales in the numerator.10 While computing inventory turnover ratios, it is always advisable to use ar figures of the cost of goods sold instead of sales but the cost of goods sold data may not be available to an out side analyst from the published annual account. In such situation inventory turnover ratio is calculated by dividing sales by the inventory. The inventory turnover ratio calculated on the basis of el the goods sold is more logical because both the numerator-the cost of goods sold and denominator-inventory are valued at cost while in the sales based inventory turnover sales are valued at market price and inventory is valued at Es t cost so they not comparable.11 The use of the cost of goods sold figures in computing inventory turnover ratio avoids any variation arising due to change in sales price therefore, it is preferred than sales. In fact when average stock is used at cost value, sales should also be used at cost value. The inventory turnover results obtained through sales figures is theoretically less valid but it can still be used for comparison and trend development purpose, especially if used consistently and when sharp changes in profit margins are not presented.12 151 Table No. 4.7 Inventory Turnover Ratio on the Basis of Sales (Rs. in millions) Year HCIL UCIL Inventory Turnover Sales Inventory Turnover 2001-02 398.6 236.56 1.685 463.9 380 1.221 2002-03 416.05 251.71 1.653 473.39 396.52 1.194 2003-04 655.4 254.52 2004-05 658.72 239.65 2005-06 655.96 230 2006-07 706.3 262.58 2.69 2007-08 989.69 283.42 2008-09 770.73 2009-10 840.5 ar Sales 546.47 462.15 1.183 2.749 532.85 493.22 1.080 2.852 709.8 477.6 1.486 505.72 530.4 0.954 3.492 552.8 638.85 0.865 345.79 2.229 675.47 753.8 0.896 378.35 2.225 694.71 816.59 0.851 Es t el 2.575 Mean 2.461 1.081 Deviation 0.551 0.199 CV 0.224 0.184 152 153 ar el Es t From the above table it is apparent that the inventories turnover ratios of both industries on the basis of sales were some how satisfactory in comparison of CGS based turn over ratios. The turn over ratio in HCIL had a fluctuating trend. In this industry the inventory turnover ratio varied from 1.653 times per year to 3.492 times per year. In year 2002-03 the inventory turnover was 1.653 times per year which implies inventory of finished goods turning to sales was 1.653 times a year or ar the HCIL was holding average inventory of 217.78 days. In year 2007-08 the inventory turnover was 3.492 times a year which indicates that the inventory of finished goods turning to sales nearly 3.5 times a year means it was holding inventory of nearly 102 days. The average inventory turnover ratio in HCIL el during the study period was 2.461 per year and its standard deviation and coefficient of variation were 0.551 and 0.199 respectively. Similarly, the inventory turnover ratio of the UCIL was not so fluctuating but it Es t was very low in comparison of HCIL. In this industry, in year 2009-10 the ratio was .85 times per year and in year 2005-06 it was 1.486 times per year indicating the lowest and highest inventory turnover ratio of the UCIL throughout the study period. It means the industry was holding finished goods inventory for more than one year period in year2007-08. In other words fund once invested in inventory had been converted into cash after 422 days. In year 2005-06 the inventory turnover ratio was highest i.e., finished goods inventory of UCIL in year 2005-06 was converted into cash nearly. The average inventory turnover ratio of UCIL was 1.081 which was very low in comparison of HCIL. Standard deviation and coefficient of variation of this industry’s inventory turnover were 0.199 and 0.184 respectively. The average inventory turnover of UCIL was very much less than average inventory turnover of HCIL in term of sales, however the coefficient of variation of inventory turnover were similar in both industries. 154 4.4 Days of Inventory Holding (DIH) Inventory holding in relation to sales is determined by calculating days of inventory holding. It is also known as average inventory period or inventory holding period. It indicates time duration of inventory holding and represents the average time taken from the purchase of raw material to the ultimate sales of finished product.13 When the number of days in a year is divided by inventory turnover we obtain days of inventory holdings. It is also called ar inventory conversion period.14 The inventory conversion period is essentially the time period during which a company must invest cash while it converts materials into a sale. Smaller the DIH higher the efficiency in managing inventory and vice versa. A high number of days of inventory holding indicate el that there is a lack of demand for the product being sold and a low days inventory holding days may indicate that the company is not keeping enough stock on hand to meet demands. The detail of inventory holding days of the Es t public cement industries of Nepal is presented below. 155 Table No. 4.8 Days of Inventory Holding HCIL UCIL 2001-02 231.79 395.84 2002-03 236.46 395.88 2003-04 183.01 426.2 2004-05 185.51 444.31 2005-06 167.21 342.02 el 2006-07 ar Year 198.08 457.97 144.74 539.06 191.66 691.16 2009-10 194.34 733.82 Mean 192.55 491.74 Standard dev. 27.021 128.69 C.V. 0.141 0.262 2007-08 Es t 2008-09 156 157 ar el Es t From the table No 4.8 and figure 5 it is clear that the average inventory holding days of UCIL were nearly 471 days which indicates no turnover of inventory even one time in a year but in the HCIL average inventory holding days were nearly 192 days which was better than that of UCIL. The inventory conversion period of UCIL was less than one year period in the year 2005-06 i.e. once in 342.02 days but in rest of eight years it was more than one year period. The higher the days of inventory holding, the smaller the liquidity of ar the firm and hence, overall profitability will also be smaller. In UCIL, due to higher days of inventory holding its annual profits throughout the study period were also poor. In this industry the smallest inventory conversion period was 342.04 days in year 2005-06 and longest inventory conversion el period was 733.82 days in year 2009-10. The standard deviation of the inventory conversion period of the UCIL was 128.69 and CV was 0.262 which indicates high fluctuation in the conversion period of inventory. Es t In comparison to UCIL the inventory conversion period of HCIL was good but it was not up to the benchmark of days of inventory holding in the manufacturing organization. In an average turnover of inventory once in each month is considered as a benchmark of inventory turnover in the manufacturing firm.15 In HCIL the shortest days of inventory holding was 144.74 in year 2007-08 and longest was 236.46 in year 2002-03 but in UCIL shortest days of inventory holding was nearly double of the longest inventory holding days of HCIL, which indicates inefficiency of UCIL in managing its assets. Test of Hypothesis To test the null hypothesis Ho: there is no significant different in the mean value of these two industries. 158 Table No 4.9 Student t- test of the Mean Value and Standard Deviation of the DIH in UCIL and HCIL (2001-2 to 2009-10) Measures HCIL UCIL t value df Result –X 186.668 470.9429 2.013 10 Not significant σ 26.1477 105.74 at 5% ar From the above table the calculated value of 't' i.e. 2.013 is less than table value of 't' i.e. 2.179 at 5% level of significant, so null hypothesis is accepted. Hence the calculated result implies that there was no significant difference in the mean value of days of inventory holding in UCIL and HCIL. el 4.5 Size of Inventory The proportion of inventory to the various forms of assets is called size of inventory. In general it is observed to find out the percentage of assets that Es t are not used to generate long term regular cash inflows. Other things being same, the higher the size of inventory in the total assets the smaller the profit of the firm and vice versa. 4.5.1 Percentage of Inventory to Total Assets One ratio used to assess operational management and inventory turnover is inventory to total assets ratio. In general, a low inventory to total assets ratio is indicative of good performance and profitability. The percentage of inventory to total assets is known as Inventory to assets ratio. It shows the percentage of the assets tied up in the form of inventory. Generally, the lower percentage value of this ratio is considered better for the company. The higher the percentage of inventory to the total assets, the lower the profitability of the firm as the opportunity cost of fund invested in the inventory will be loosened.16 159 Companies with high inventory turnover generally will have a low percentage of inventories to total assets. By looking at the inventory to total assets ratio over time, one can determine inventory levels for the company. If the ratio is rising, inventory levels are increasing, which may be a sign of low demand and over supply of the inventoried asset. Financial analysts consider such situation as a negative sign. Conversely, if inventory levels are decreasing, it may be a sign of increased demand which ar points to a higher level of profitability. The ratio of inventory to total assets computed for the selected non finance Nepalese enterprises according to ministry of finance in 2001 was about 22%. el To invest on an average, about 22% of total assets in the form of inventories by Nepalese enterprises indicates that larger amount of money has been invested in the form of inventory which is not good sign of assets allocation. The percentage of inventory to total assets in public cement industry of Nepal Es t is as under. 160 Table No. 4.10 Percentage of Inventory to Total Assets (Rs in millions) Year HCIL Total UCIL Inventory Percentage Assets of Total Inventory Percentage Assets of 13.74 inventory 2001-02 1720.82 236.56 2002-03 1735.73 251.71 2003-04 1762.05 254.52 2004-05 1792.43 239.65 ar inventory 4687.23 380 2005-06 1831.6 2006-07 1823.41 262.58 4571.18 396.52 8.6 14.44 4451.6 462.15 10.38 13.92 4209.6 493.22 11.17 12.55 3986.4 477.6 11.98 14.4 3952.62 530.4 13.41 el 14.5 Es t 230 8.10 2007-08 1907.67 283.42 14.85 3781.05 638.85 16.89 2008-09 2028.17 345.79 17.04 3655.23 753.8 20.62 2009-10 2118.96 378.35 17.86 3579.23 816.59 22.81 Mean 14.80 13.77 Standard 1.39 4.02 0.094 0.29 Dev C. V. 161 162 ar el Es t The ratios of inventory to total assets in both industries during the study period were between 8.6 to 20.62 percent. In the HCIL the ratio was best in the year 2005-06 and worst in 2008-09 because the lower percentage value of this ratio is an indicative of better inventory performance. The average value of this ratio in the HCIL was 14.80 percent and standard deviation of the ratios during the study period was 1.39 percent. The above calculations show that HCIL has low variability in its inventory to ar total assets ratio as a result its C.V. was also lowest (.094) indicating high consistency in maintaining the inventory in relation to total assets. In comparison to HCIL the inventory to total assets ratios of the UCIL were not so consistence. In the year 2001-02 it was 8.10% at the end of the study period el (2009-10) it became nearly 23% meaning that in the UCIL there was high variation in this ratio during the study period. The average value of this ratio in UCIL was 13.77% and standard deviation was 4.02% which indicates greater Es t variability of the ratio in comparison to HCIL. The consistency of the ratio in this industry was also poor which was clearly indicated by the value of C.V. 4.5.2 Percentage of Inventory to Current Assets Current assts, sometimes called liquid assets, are those resources of the firm which are either held in the form of cash or are expected to be converted in cash within the operating cycle of the firm. The operating cycle is the time taken to convert the raw materials into finished goods, selling finished goods and convert receivable into cash. Current assets include cash, marketable securities, receivable and inventories.17 The quality of current assets has been viewed in term of liquidity of current assets therefore, the high ratio of cash to current assets indicates qualitative current assets and high ratio of inventory to current assets indicates less qualitative current assets. The higher ratio of inventory to current assets 163 would indicate a large volume of inventory holding. There is an opportunity cost of holding inventory that grows inventory cost and hence reduces profit of the firm. Therefore, higher percentage of inventory to current assets can be taken as a sign of poor inventory management.18 The ratio of inventory to current assets of the public cement industries of Nepal has been presented in the following table in the form of percentage. Table No. 4.11 Year HCIL 2001-02 367.46 2002-03 393.69 Inventory Percentage Current Assets Inventory Percentage 236.56 380 48.24 64.38 787.68 251.71 63.93 704.59 396.52 56.27 254.52 56.3 636.07 462.15 72.64 Es t 2003-04 452.11 UCIL el Current Assets ar Percentage of Inventory to Current Assets (Rs. In millions) 2004-05 471 239.65 50.87 784.69 493.22 62.88 2005-06 527.45 230 43.61 852.55 477.6 56.02 2006-07 537.54 262.58 48.83 896.03 530.4 59.15 2007-08 625.61 283.42 45.3 1026.1 638.85 62.18 2008-09 639.08 345.79 54.11 1122.1 753.8 67.18 2009-10 685.17 378.35 55.22 1173.9 816.59 69.56 Mean 53.61 62.57 Std. 6.62 5.49 0.12 0.087 Dev. C. V. 164 ar el Es t From the table no. 4.11 and figure 8 & 9 above it is clear that the ratios of inventory to current assets of HCIL were comparatively lower than that of UCIL except in year 2002-03. The percentage of inventory to current assets of 165 HCIL was highest (nearly 70%) in year 2002-03 and lowest in year 2005-06 with 43.61%. The average percentage of inventory to current assets of HCIL was 53.61 which denote that the industry was holding about 50% of its current assets in the form of inventory. The variability of this percentage measured in term of standard deviation was 6.62 and coefficient of variation was .12 that indicates minor fluctuations. As there is no universal standard for this ratio since each industry has its own ar pattern of inventory requirement therefore, the ratio of inventory to current assets is determined by their own need.19 In HCIL the ratios of inventory to current assets from 2001-02 to 2009-10 were found in haphazard trend i.e. sometime increasing and sometime decreasing. It means the industry was el open regarding the percentage of inventory to current assets which is not good from the view point of profit earning organization. Similarly the percentages of inventory to current in the UCIL were also in Es t stochastic trend. In year 2001-02 it was 48.24% then increase to 72.64% in year 2003-04 then for the next two years it decrease. From 2006-07 it continuously increased and became 69.56% in year 2009-10. The average percentage of inventory to current assets of the UCIL was 62.52% which was neatly 12% greater than the average inventory turnover of the HCIL. The year wise ratio of inventory to current assets in HCIL indicates that the share of inventories in the current assets- some how- has decreased but in UCIL it has increased. It shows that current assets of the HCIL and UCIL were less qualitative over the time as inventory is the least liquid form of current assets. A comparison of ratios of inventories to current assets for the individual industries, it may be noticed that the ratio has increase for both industries over a period of time. The above analysis indicates that the Nepalese cement industries were not given due importance to inventory management as the share of inventories in the current assets has been largest during the study 166 period, therefore they are recommended to give considerable importance to the inventory management. 4.6 Linking Inventory Management to Profitability Profit is the ultimate goal of the company and it will have no future if it fails to make sufficient profits; therefore, every company should earn profit to survive and grow over a long period of time. In general, profitability is the ar net result of a number of policies and decisions. The efficiency of a company at generating earnings is called profitability. In other words the efficiency of a company in term of profit is called profitability. The profitability of a company is measured in term of profitability ratio which el shows combined effects of liquidity, assets management and debt management on operating results. 20 Inventory management has a significant influence on profitability. Profit is the Es t difference between revenues and expenses over a period of time. The expenses in the context of manufacturing company denote costs of production. The cost of production consists various components including raw material, labour, overhead, etc. and out of total cost of production the percentage of raw material and spare parts would be about 60%. If these two major components of the cost of production are managed efficiently the firm would be able to reduce inventory holding cost significantly, as a result it can increase overall profitability.21 4.6.1 Inventory to Profit Ratio Just as a business net profit margin can affect the way it manages its inventory, inventory management also can have a direct impact on sales and as a result, change profit margins. This is a result of a business ability to maintain inventory of its production and to meet customer demand. 167 Other things being same, the higher the volume of inventory holding the smaller will be the percentage of gross profit margin on inventory investment. Large quantity of inventories indicates low sales, and low sales generate low profit. The percentage of operating profit on inventory investment of the public cement industries of Nepal is presented below. Table No. 4.12 Inventory to Profit Ratio of HCIL Year Inventory ar (Rs. in millions) Change in Profit Change in Inv/Profit Profit Ratio - Negative Inventory 236.56 - (7.84) 2002-03 251.71 15.15 (13.82) (5.98) Negative 2003-04 254.52 2.81 96.6 109.82 37.95 Es t el 2001-02 2004-05 239.65 (14.87) 139.97 43.37 58.4 2005-06 230 (9.65) 105.66 (34.31) 45.94 2006-07 262.58 32.58 154.3 48.64 58.76 2007-08 283.42 20.84 180.97 26.67 63.9 2008-09 345.79 62.37 (4.8) (185.77) Negative 2009-10 378.35 32.56 5.6 10.14 37.31 168 ar el The above table 4.12 and figure 10 exhibit the percentage of operating profit Es t to inventory of HCIL during the study period. It indicates that the percentage of profit was registered negative in the year 2001-02, 2002-02 and 2008-09 and found maximum 63.9% in 2007-08 showing a fluctuating trend. In the year 2001-02, 2002-03 and 2008-09 the industry suffered loss thus it has negative value of the inventory to profit ratios in these years. Also, this table clearly exhibits the positive correlation between inventory and profitability in this industry because in the year 2003-04 it had inventory of Rs. 254.52 million and operating profit of Rs. 96.6 millions whereas, in the next year 2004-05 the value of inventory decreased to Rs. 239.65 millions but the amount of profit increased to Rs. 139.97 millions. Similarly, in year 2005-06 the value of inventory decreased by Rs. 9.65 millions but profit was not increased rather it decreased nearly by Rs. 35 millions. The most striking feature of the table No. 4.11 is that the inventory holding and profitability of this industry seems quite contradictory with the well 169 established principles of inventory management and profitability of the firm. Due to high percentage of stores and spare part inventory, which are mostly remaining idle in the stock, the profitability of this industry has not followed the trend of inventory holding. Table No. 4.13 Inventory to Profit Ratio of UCIL (Rs. In millions) Inventory Change in Profit Inventory - Change in INV/Profit ar Year Profit Ratio 105.4 - 27.73 83.96 (21.44) 21.17 2001-02 380 2002-03 396.52 2003-04 462.15 65.63 114.37 30.41 24.74 2004-05 493.22 31.07 87.14 (27.23) 17.67 2005-06 477.6 (15.62) 150.04 62.9 31.46 2006-07 530.4 52.8 36.34 (113.7) 6.85 2007-08 638.85 108.45 63.12 26.78 9.88 2008-09 753.8 114.95 228.72 165.6 30.34 2009-10 816.59 62.79 93.23 135.49 30.15 Es t el 16.52 170 171 ar el Es t From the above table 4.13 and figure 11 it is evident that in UCIL there was less fluctuating trend in the value of percentage of inventory to profit during the period of study in comparison to HCIL. It was maximum 31.46 in 2005-06 and minimum 6.85 in year 2006-07. This table clearly exhibits that in most of the years (three out of eight) there was positive correlation between inventory holding and amount of profit and for the rest five years it was negative. In the year 2001-02 profit was Rs. 105.4 million and inventory was ar Rs. 380 million. In the year 2002-03 there was inventory of Rs. 396.52 millions and operating profit Rs. 83.96 millions whereas, in the next year 2003-04 the value of inventory increased to Rs. 462.15 and the amount of profit also increased to Rs. 114.37 that shows positive correlation between these two el variables but in the next three years the correlation is negative. Then for the next two years their correlation again exists positive but in the final year there exists negative correlation between these two variables. As comparing, these two industries the inventory management practice of UCIL seems better than Es t that of HCIL in terms of profitability. 4.6.2 Gross Margin Return on Inventory (GMROI) Like most manufacturers, cement industries are no doubt concerned with inventory management. They invest a lot of time and money for incorporating MRP, JIT, ABC, and other techniques into their inventory management systems or, they concentrate on managing gross margins. An important area for linking inventory management to the profitability of the firm that’s often misunderstood is the relationship between turnover, margins, and profitability. Effective asset management is one of the primary means of improving overall profitability of the manufacturing companies. But assets can’t be managed effectively as a whole thus; they must be managed individually. Because inventory is among a manufacturer’s largest assets therefore, effective management of inventory is critical to profitability. Three 172 benchmarks of inventory management effectiveness are of particular importance to manufacturers. The overall measures of inventory productivity are: (1) Gross margin percentage (2) Inventory turnover and (3) Gross margin return on inventory. ar A calculation which determines the gross margin is earned by the company by its products or services and whether or not a company can efficiently turn inventory into cash at acceptable margins is called Gross Margin Return On el Inventory (GMROI).22 An important tool in analyzing inventory, sales and profitability is GMROI also known as GMROII which stands for gross margin return on inventory investment. The GMROI calculations assist manufacturer in evaluating Es t whether a sufficient gross margin is being earned by the products sold, compared to the investment in inventory required to generate those gross margin. Gross margin return on inventory is considered the best single measure of inventory management effectiveness because it includes gross margin component as well as an inventory movement component. GMROI analysis provides three important benefits. (i) It shows how inventory buying and pricing procedures be combined with inventory management procedures to affect profitability. (ii) It shows how products with a relatively low gross margin and high turnover can be just as profitable as those with higher margins and lower turnovers. (iii) It demonstrates that as gross margins decrease, inventory turnover must increase otherwise profitability will suffer. 173 Gross Margin Return on Inventory (GMROI) is a "turn and earn" metric that measures inventory performance based on both margin and inventory turnover. In essence, GMROI answers the question, "For every rupee carried in inventory, how much is earned in gross profit?" In the calculation of GMRIO two terms are incorporated in the formula i.e. earns term and turn term. The earn term, gross profit/sales, is simply the gross profit margin percentage on sales. The turn term, sales/average Inventory at cost same as inventory ar turnover, which is the cost of goods sold, divided by average Inventory at cost. Therefore, the GMROI formula can be simplified to address the impact of these two terms in a single formula GPM% × ITO 1-GM% el GMROI = or GMROI = Gross Margin Inventory Es t GMROI has been used much less frequently in manufacturing organizations, most likely because of the difficulty of associating raw material inventory with specific end item products. However, with much more extensive databases and data collection along with a shift to the greater use of contract manufacturing, it can be possible to calculate and track GMROI in manufacturing organizations as well. 174 Table No. 4.14 Gross Margin Return on Inventory (GMROI) of HCIL (Rs. In millions) Particular 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 398.6 416.05 655.4 658.72 655.96 706.3 898.69 770.63 840.5 Less CGS 372.5 388.54 507.61 471.54 502.04 483.83 714.7 658.52 710.63 Gross M. 26.1 27.51 147.78 187.54 153.93 222.24 275.55 112.20 129.87 Inventory 236.56 251.71 254.52 239.65 230 262.58 283.42 345.79 378.35 Gross M.% 6.55 6.61 22.55 28.47 23.46 31.46 27.84 14.56 15.45 Inventory 1.575 1.544 1.995 1.968 2.183 1.843 2.522 1.91 1.878 97.30 32.54 34.32 GMROI(%) 11.03 el turnover ar Sales 10.93 78.33 66.91 Standard Deviation=30.03 Es t Average GMROI=52.67% 58.08 175 84.59 C.V.=.57 The measures of the gross margin return on inventory of the HCIL presented above in table No. 4.14 and figure 12 shows that the industry was earning on an average of 52.67% on inventory investment during the study period. It means that for every rupee invested in inventory, the industry was getting back on an average Rs. 1.5267 to pay expenses and make a profit. The gross margin return on inventory was very low (10.93%) in year 2002-03 and it was very high (97.30%) in year 2007-08. The coefficient of variation of ar this percentage was very high i.e. 52.67% which indicates inconsistency of gross margin return on inventory in this industry. The advantage of this measure is that one may assess the impact of inventory turnover upon the GMROI. For example, in the table above the percentage of gross profit margin el was greater (31.46) in the year 2006-07 and was smaller (27.84) in year 200708. However, when we look in the GMROI row of the table the figure is quite opposite because in the year 2007-08 the industry has turned its inventory Es t more than that of the year 2006-07. Gross margin return on inventory is considered the best single measure of inventory management effectiveness as, it shows how a relatively low gross margin can be enhanced into high profitability by using high turnover. The gross margin return on inventory includes Inventory related expenses as well profit. As the inventory related costs on the Nepalese cement industries are remarkably high so, on an average 61% gross margin earned on inventory cannot be considered satisfactory. Therefore, this industry is suggested to increase the times of inventory turnover so as to increase net earning on inventory investment. 176 Table No. 4.15 Gross Margin Return on Inventory (GMROI) of UCIL (Rs. In millions) Particular 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 463.9 473.39 546.47 532.85 709.8 505.72 552.8 675.47 694.71 Less CGS 350.4 365.58 395.77 405.17 509.68 422.74 432.57 398.06 406.21 Gross M. 113.4 107.81 50.7 127.68 200.12 82.98 120.23 277.41 288.5 Inventory 380 396.52 462.15 493.22 477.6 530.4 638.85 753.8 816.59 Gross M.% 24.4 22.77 27.58 23.96 28.19 16.41 21.75 41.69 41.53 .921 0.922 0.856 0.822 1.067 0.797 0.677 0.528 .497 18.82 37.75 35.33 Inventory GMROI(%) 29.84 el turnover ar Sales 27.18 25.90 41.88 Standard Deviation=8.29% Es t Average GMROI=29.77% 35.6 177 15.64 C.V.=0.278 From the table No. 4.15 and figure 13 it is observed that the inventory turnover ratios of UCIL was less than one during a year except in year 2005-06 meaning that inventory conversion period of this industry was more than one year. Due to this reason the gross margin return on inventory of the industry were comparatively smaller than that of HCIL. The gross margin return on inventory was lowest (15.64%) in year 2006-07 and it was highest (41.88%) in year 2005-06. It means on the whole the percentage of GMROI marked a ar fluctuating trend. The average value of this percentage was 29.77% and coefficient of variation was 0.279 indicating nearly 27% fluctuation in the gross margin return on inventory investment during the study period. While comparing the GMROI of these two industries obviously HCIL seems better in el term of annual and average GMROI during the study period but in term of variability of the GMROI UCIL exhibits better performance. Es t 4.7 Statistical Analysis Statistical analysis refers to a Collection, examination, summarization, manipulation, and interpretation of quantitative data to discover its underlying causes, patterns, relationships, and trends. It provides ways to objectively report on how unusual an event is based on historical data. 4.7.1 Correlation Analysis The correlation is one of the most common and most useful statistics. A correlation is a single number that describes the degree of relationship between two variables. The correlation analysis is generally used to describe the degree to which one variable is related to another. It helps to determine whether a positive or a negative relationship exists. The positive correlation indicates that increase in value of one variable leads to increase in value of other variable, and the negative correlation indicates that increase in value of one variable leads to decrease in value of the other variable. The correlation 178 coefficient lies between +1 and -1. The +1 coefficient indicates that the variables are perfectly positively correlated and -1 coefficient indicates that the variables are perfectly negatively correlated. And if the correlation coefficient is 0, it means that the variables are not related to each other. The number indicates the degree of correlation between the variables. 4.7.2 Correlation between Sales and Inventory ar Theoretically, the correlation between inventory and sales must be negative. As per objective of the study the correlation between sales and inventory of the public cement industries in Nepal is calculated and interpreted in the following. el Table No. 4.16 Es t Correlation Coefficient between Sales and Inventory in the Public Cement Industries of Nepal (Rs. In millions) Year HCIL UCIL Sales (X) Inventory (Y) Sales (X) Inventory (Y) 2001-02 398.6 236.56 463.9 380 2002-03 416.05 251.71 473.39 396.52 2003-04 655.4 254.52 546.47 462.15 2004-05 658.72 239.65 532.85 493.22 2005-06 655.92 230 709.8 477.6 2006-07 706.3 262.58 505.72 530.4 2007-08 898.69 283.42 552.8 638.85 2008-09 770.63 345.79 675.47 753.8 2009-10 840.5 378.35 694.71 816.59 Mean 676.93 275.84 572.78 549.9 S. D. 161.34 36.61 83.71 115.34 C. v. 0.238 0.137 0.146 0.209 Correlation(rxy) 0.43 Probable Error 0.29 0.59 0.23 179 Table No. 4.16 shows the relationship between actual sales and inventory of the public cement industries of Nepal during the nine year period. From the above table it is evident that in HCIL the actual sales which increase over the period but the increment in the inventory has not followed the same trend. Sales were increase for four years and decrease in fifth year then increase in sixth and seventh year. In the eighth year it has decreased and in the final year increased again. On the other hand inventory increased for three years and ar decreased for another two years and for the rest period it was in the increasing trend. However, the change in these two variables was not well defined; there was intermittent rise and fall during the nine years. Mean, standard deviation and coefficient of variation were calculated to el analyze the nature of the variability of sales and inventory in both industries. The average value of the sales and inventory in HCIL ware 676.93 and 275.84 respectively. The deviation of annual sales and inventory from average value Es t calculated as standard deviation in this industry were 161.34 and 36.61 respectively. The variability of these two variables calculated in term of coefficient of variations were 23.8% and 13.7% respectively. This signifies that inventory was more consistent as compared to sales. In UCIL sales were increased for the first three years and decreased in the fourth year. In the fifth year sales were again increased and in the next year it decreased then after it continuously increased up to the final year but inventory followed an increasing trend for all nine years during the study period. This table also depicted that the increase in sales resulted into increase in inventory in UCIL and the intermittent trend of sales increase in HCIL has not directly affected in the inventory value. In UCIL average sale was 572.78 with standard deviation of 83.71 signifying the either deviation of annual sales from average sales. Similarly average inventory was 549.9 with standard deviation of 115.34 relatively less deviated as compared to sales. Relating to the uniformity and stability sales were found relatively stable in 180 comparison of inventory which is shown by lower value of coefficient of variation for sales 14.6% compared to that of inventory 20.9%. On the other hand, correlation coefficients were calculated for the both industries to analyze the relationship between sales and inventory. The value of coefficient of correlation always lies between +1 and -1. A value -1 indicates a perfect negative relationship between the variables and a value of +1 indicates a perfect positive relationship. A value of zero indicates that there is ar no relation between the variables. The positive value of correlation coefficient between these two variables justify movement of both variables in the same direction i.e. increase in sales cause to increase in inventory and vice versa. el Coefficient of correlation of sales and inventory in UCIL was 0.59 which signifies high positive relationship. High positive correlation implies that a certain percent increase in one variable cause to increase for about same percentage increase in the other variable and vice versa. In other words 59% Es t variation on inventory was due to sales. Theoretically, the correlation coefficient between inventory and sales must be negative but in our calculation for the UCIL it was positive which indicates less effectiveness of the inventory management in this industry. Probable error was also measured to ascertain the reliability of the value of correlation coefficient and conclude whether simple correlation coefficient is significant or not. Principally, the value of correlation coefficient must be 6 times smaller than the value of probable error. Here, r<6PE i.e. 0.62< .22x6=1.32) shows that the coefficient correlation is significant meaning that the relationship of these two variables is highly interdependent. In the HCIL the coefficient correlation between inventory and sales was 0.43 and probable error was 0.3 which implies that the coefficient correlation is significant because 6 times value of probable error would be 1.8 which is greater than simple correlation coefficient. 181 4.7.3 Correlation between Profit and Inventory Without an effective and efficient management of inventory no organization can achieve their goals. Inventory management helps to maximize the profit of the firm. Higher the volume of inventory smaller the amount of profit so there is always negative relationship between the inventory holding and the profitability of the firm. To examine this established principle the correlation between inventory and profit of the public cement industries in Nepal is ar calculated and interpreted in the following. Table No.4.17 Correlation Coefficient between Inventory and profit in the Public Cement Year el Industries of Nepal HCIL Profit(X) Inventory (Y) UCIL Profit(X) Inventory (Y) (7.84) 236.56 105.4 380 2002-03 (13.82) 251.71 83.96 396.52 2003-04 96.6 254.52 114.37 462.15 2004-05 139.97 239.65 87.14 493.22 2005-06 105.66 230 150.04 477.6 2006-07 154.3 262.58 36.34 530.4 2007-08 180.97 283.42 63.12 638.85 2008-09 (4.8) 345.79 228.72 753.8 2009-10 5.6 378.35 93.23 816.59 Mean 72.96 275.84 103.92 549.9 S. D. 66.97 36.61 59.27 115.34 C. V. 0.92 0.137 0.57 0.209 Es t 2001-02 (Rs. In millions) Correlation(rxy) (0.34) 0.45 182 From the above table it is evident that in HCIL the annual profit which increases over the period but the increment in the inventory has not followed the same trend. In the year 2001-02 and 2002-03 the operating profits of HCIL were negative it started to increase except negative in year 2008-09. On the other hand inventory showed increasing trend throughout the study period. However, the change in these two variables was not well defined i.e. there was intermittent rise and fall during the nine years. ar Mean, standard deviation and coefficient of variation calculated to analyze the nature of the variability of sales and inventory in both industries showed the average value of the profit and inventory in HCIL were 72.96 and 275.84 respectively. The deviation of annual profit and inventory from average value el calculated as standard deviation in this industry were 66.97 and 36.61 respectively. The variability of these two variables calculated in term of coefficient of variations were 34% and 13.7% respectively. This signifies that Es t inventory was more consistent as compared to profit. In UCIL in year 2003-04 profit was increased then in year 2005-05 it was decreased. In the fifth year the amount of profit again increased then for the next two years it has decreased and in year 2008-09 the amount of profit increased to Rs. 228.72 millions but in the final year it decreased to Rs. 93.23 million. On the other hand inventory followed an increasing trend for all nine years during the study period. This table also depicted that the increase in inventory resulted into increase in profit in UCIL and the intermittent trend of profit increase in HCIL has not directly affected in the inventory value. In UCIL average profit during the nine year period was 103.92 with standard deviation of 59.27 signifying the either deviation of annual profit from average profit. Similarly average inventory was 549.9 with standard deviation of 115.34 relatively less deviated as compared to profit. Relating to the variability and inconsistency; profits were found relatively unstable in 183 comparison of inventory which is shown by higher value of coefficient of variation for profit 57% compared to that of inventory 20.9%. On the other hand, correlation coefficients were calculated for the both industries to analyze the relationship between profits and inventory. The coefficient of correlation of profit and inventory in UCIL was 0.45 which signifies high positive relationship. High positive correlation implies that a certain percent increase in one variable cause to increase for about same ar percentage increase in the other variable and vice versa. The co-efficient of correlation between Profit and inventory in UCIL indicated high degree of positive association that is not supported statistically. But there are other factors like capacity utilization, reputation of product and mobilization of el other financial resources affecting the profitability of the industry. In the HCIL the coefficient correlation between inventory and profit was (0.34) or Negative. Negative value of correlation coefficient implies that an increase Es t in one variable cause to decrease in the other variable. Theoretically, an increase in inventory cause profit to decrease therefore, the inventory management practice in HCIL in term of correlation between inventory and profit is found statistically significant or in consonance with established principle. 4.8 Regression Analysis Regression analysis in the general sense denotes the estimation or prediction of the unknown value of one variable from the known value of other variable. It is especially used in business and economics to study the relationship between two or more variables that are related casually. In other words regression analysis is used to determine the statistical relationship between two or more variables and to make prediction of one variable on the basis of the others. 184 4.8.1 Regression on Inventory and Sales To analyze the relationship between sales and inventory of the cement industries, here inventory is assumed as a dependent variables and denoted by ‘Y’ and sale as independent variables denoted by ‘X’. The regression equation of Y on X, which is used to describe the variation in the value of Y for a given change in the value of X, is ar Y = a + bx Where, Y = inventory a = Intercept or mean value of Y. X = Sales. el b = Slop of trend line. Table No. 4.18 Es t Calculation of Regression of Inventory on Sales of UCIL and HCIL Year UCIL (Rs. In millions) HCIL Sales(X) Inventory(Y) Sales(X) Inventory(Y) 2001-02 463.9 380 398.6 236.56 2002-03 473.39 396.52 416.05 251.71 2003-04 546.47 462.15 655.4 254.52 2004-05 532.85 493.22 658.72 239.65 2005-06 709.8 477.6 655.92 230 2006-07 505.72 530.4 706.3 262.58 2007-08 552.8 638.85 898.69 283.42 2008-09 675.47 753.8 770.63 345.79 2009-10 694.71 816.59 840.5 378.35 185 According to these data the regression equation of inventory (Y) on sales (X) of HCIL as calculated and shown in appendices is as under. Y = 149.12 + 0.1899x The above regression result shows that there was positive relationship between sales and inventory of the HCIL. The constant value 149.12 indicate that the value of sales would be Rs. 149.12 million irrespective of changes in inventory while coefficient value 0.1899 indicate the changes in Rs. 1 of ar inventory cause to change Rs. 0.1899 of sales of the industry. In other words the slop coefficient of 0.1899 produced by regression equation in HCIL implies that the marginal propensity to change in sales was nearly 19% due to change el in inventory. Similarly, the regression equation calculated on the basis of sales and inventory data of UCIL as calculated and shown in appendices is as under. Es t Y = -87.89 + 1.1135x In the UCIL the slop coefficient was 1.1135 meaning that, if the value of inventory increase by a rupee on an average the value of sales would increase by Rs. 1.1135. The intercept value of ‘a’ -87.89 implies that the average value of sales would be negative by Rs. 87.89 million if inventories were zero. The linear regression equation of inventory and sales in UCIL indicates that if the industry invests Re. 1 in inventory sales would be Rs. 1.1135. 4.8.2 Regression on Inventory and Profit To analyze the relationship between inventory and profit of the cement industries, here inventory is assumed as dependent variables and denoted by ‘Y’ and profit as independent variables denoted by ‘X’. The regression equation of Y on X, which is used to describe the variation in the value of Y for a given change in the value of X, isY = a + bx 186 Table No. 4.19 Calculation of Regression of Inventory on Profit of UCIL and HCIL (Rs. In millions) Year UCIL Inventory(Y) HCIL Profit(X) Inventory(Y) Profit(X) 380 105.4 236.56 (7.84) 2002-03 396.52 83.96 251.71 (13.82) 2003-04 462.15 114.37 254.52 96.6 2004-05 493.22 87.14 239.65 139.97 2005-06 477.6 150.04 230 105.66 2006-07 530.4 36.34 262.58 154.3 2007-08 638.85 63.12 283.42 180.97 2008-09 753.8 228.72 345.79 (4.8) 2009-10 816.59 93.23 378.35 5.6 Es t el ar 2001-02 According to these data the linear regression equation on profit and inventory in HCIL as calculated and shown in appendices is as under. Y = 293.34 + (–0.2318) x The above equation shows negative relationship between inventory and profit in HCIL. The negative slop coefficient indicates that one rupee increase in the inventory investment cause to decrease profit by Rs. 0.2318. In case of UCIL the linear regression equation of inventory and profit is as under. Y = 464.42 + 0.7995 x The equation shown above indicates positive relationship between inventory and profit in UCIL. The slop of the trend line in this industry was 0.7995 meaning that if the value of inventory increase by rupees hundred profit would increase by rupees 79.95. 187 Test of Hypothesis There is no impact of inventory management on the profitability of the cement industries of Nepal. Table No. 4.20 Correlation, regression and their student t-value of HCIL and UCIL (2001-02 to 2009-10) Correlation HCIL (0.34) UCIL d. f t- value 8 2.4 0.45 Result Significant at ar Measures 5% level Y = 293.34 + Y = 464.42 + (–0.2318)x 0.7995x el Regression From the table No. 4.20 the calculated value of ‘t’ is more than table value of ‘t’. So the null hypothesis is rejected means there is significant impact of Es t inventory management in the profitability of the cement industries of Nepal. The rejection of null hypothesis means acceptance of alternate hypothesis. Therefore, according to alternate hypothesis there is significant impact of inventory management on overall profitability in the Cement Industry of Nepal. 4.8.3 Multiple Regression Analysis The multiple regression equation of X1 on X2 and X3 is X1 = a + b1x2 + b2x3 Here, Profit (X1) = Dependent variable Sales (X2) and Inventory(X3) = Independent variables. 188 Table No. 4.21 Calculation of Multiple Regression on Inventory, Sales and Profit of UCIL and HCIL (2009-10) (Rs. in millions) Year UCIL HCIL Inventory Profit Sales Inventory Profit Sales (X3) (X1) (X2) (X3) (X1) (X2) 463.9 236.56 (7.84) 398.6 473.39 251.71 (13.82) 416.05 380 105.4 2002-03 396.52 83.96 2003-04 462.15 114.37 546.47 254.52 96.6 655.4 2004-05 493.22 87.14 532.85 239.65 139.97 658.72 2005-06 477.6 150.04 709.8 230 105.66 655.92 2006-07 530.4 36.34 505.72 262.58 154.3 706.3 2007-08 638.85 63.12 552.8 283.42 180.97 898.69 2008-09 753.8 228.72 675.47 345.79 (4.8) 770.63 2009-10 816.59 93.23 694.71 378.35 5.6 816.59 Es t el ar 2001-02 On basis of variables the multiple regression equation of profit on inventory and sales of UCIL as calculated and shown in appendices is as under. X1 = 77.1869 + (0.0872) X2 + 0.1402X3 The above multiple regression equation shows that there is both negative and positive relationship among the profit, sales and inventory. The intercept value of 77.1869 means that profit in UCIL would be Rs. 77.1869 million even if sales and inventory were zero. Similarly the coefficient of X2 0.0872 and X3 0.1402 indicate that when sales increase by Re. 1 profit would increase by Rs. 0.1402 and inventory would decrease by Rs. 0.0872. 189 The multiple regression equation of HCIL for inventory on sales and inventory as calculated in appendices is as under. X1 = –335.43 + (–0.1129) X2 + 1.7494X3 This multiple regression equation clearly indicates that profit of the HCIL would be negative by Rs. 335.43 if sales and inventory were zero. This equation also indicates that there is negative and positive relationship between sales, inventory and profit in the HCIL. The regression coefficient O.1129 and sales by Rs. 1.7494. ar implies that to increase profit by rupee one inventory need to decrease by Rs. 4.9 Analysis of Primary Data el An empirical investigation has been conducted in order to identify the problems faced by the cement industries in Nepal. For this purpose a total 25 set of questionnaires with 45 questions in each set were developed and Es t distributed in the 5 cement industries (5 in each industry) to collect information in the various aspect of inventory management. To explore inventory management problem faced by the cement industries of Nepal 2 public and 3 private cement industries were selected and in each industry five concerned departmental head (procurement, production, finance, account and administration) were consulted to fill the questionnaires. In the questionnaires of different aspect of inventory management like inventory policies, motive for inventory holding, determining the size of inventory, practices of maintaining safety stocks, fixation of reorder point, lead time analysis, inventory control system and application of computers in controlling inventory were raised and required to answer. The questionnaires were asked either for yes/no answer or for choosing one out of the given alternatives. Some questions were also asked to give their opinions. The response of questionnaires was not so good. The responses 190 received from various respondents have been arranged and analyzed in order to facilitate the descriptive analysis of the study. Opinions/views given by the respondents are expressed in percentage to show result obtained from primary data. Table No. 4.22 Analysis of Primary Information Collected Through Questionnaires S.N. Issues Raised No. of Yes No Setting inventory policies 20 8 12 2 Motives of inventory holding 16 7 9 3 Determination of EOQ 23 4 19 4 Practice of keeping safety stocks 21 9 12 5 Fixation of reorder point 19 13 6 6 Lead time analysis 22 18 4 7 Inventory control system 21 11 10 21 9 15 Es t el 1 ar Respondents 8 Application of computer in controlling inventory From the above table it became clear that the tools and techniques of managing inventory have not properly been applied in Nepalese cement industries for controlling their physical and financial dimension. Due to the lack of proper inventory policies and practices they are blocking large amount of capital in inventory and hence, facing the problem of inadequate profitability. Inventory policies Inventory policies concern with the establishment of guidelines relating to inventory. Most of the Nepalese cement industries were found without inventory policies because among 20 respondents in this issue 12 respondents (60%) accepted that their industry does not set inventory policies. 191 Motives of inventory holding Maintaining inventories involve tying up of companies fund and incurrence of storage and handling cost. Every firm knows this reality of the inventory holding even though they hold inventories. There are three general motives for holding inventory i.e. transaction, precautionary and speculative. In the context of cement industries in Nepal the majority of the respondents 9 out of 16 or 56% replied that their industry hold inventory with a view to meet day ar to day operation of the industry and few answered in fevour of precautionary motive. It means the basic motives for holding inventory in most of Nepalese cement industries were transaction and precautionary. el Determination of EOQ Economic order quantity (EOQ) is that size of the order which gives maximum economy in purchasing any material and ultimately contributes towards Es t maintaining the materials at the optimum level and at the minimum cost. Out of 23 respondents only 4 replied that inventories are purchased and hold on the basis of costs effectiveness. 19 respondents out of 23 or nearly 82% answered that their industry never calculated Economic Order Quantity which indicates the weakest part of inventory management in the Nepalese cement industries. Fixation of reorder point As its name suggests, re-order point determines the amount of inventory at which the stores or purchase department should order new stocks of raw materials to replenish supplies to the optimum quantity. In the issue of reorder point majority of the respondents mentioned that reorder point is determined in their industry and orders are placed accordingly. Among 19 respondents 13 or nearly 68% answered that raw materials and fuels are 192 purchased as per schedule date fixed by the procure department at the very beginning of the month. Lead time analysis The term lead-time refers to the time normally taken in reciving the delivery after placing orders with the suppliers. It covers the time span form the point when the decision to place the orders for the procurement of inventory is ar made to the actual receipt of the inventory by the firm. In the Nepalese cement industries as per respondents answer lead time is normally estimated on the basis of past experiences and new order is placed by cosidering the margin of lead time. Out of 22 respondents in this issue 18 (81%) replied that el lead time is always adjusted in placing the new order, it means there is practice of lead time analysis in the cement industries of Nepal. Inventory control system Es t An inventory control system is a system of maintaining record by the procurement department which reflects the physical movement of stocks and their current balance. In other words it is a process for managing and locating inventory objects or materials. Inventory objects could include any kind of physical asset, merchandise, consumables and fixed assets, circulating tools or capital equipment. The most important objective of inventory control is to determine and maintain an optimum level of investment in the inventory. In the context of cement industries in Nepal the practice of inventory control was found some how satisfactory because out of 21 respondents in this issue 11 respondents or nearly 52% accepted the fact that inventories in their industry are controlled by the store section through records in computer and ledger. Although nearly 50% respondents replied that their organization does not apply any system for controlling the physical and financial dimension of the inventory. 193 Application of computer in controlling inventory The use of computer in inventory management increases their productivity and maintains competitiveness. In the modern business environment, even many smaller businesses have come to rely on computerized inventory management systems. For the manufacturing firms operating with high volume of turnover of raw materials and/or finished products, computerized inventory control systems have emerged as a key component of business ar strategies. In Nepal the practice of using computer for record keeping is a new concept. In Nepalese cement industries the application of computer for recording and controlling inventory was found very poor because 15 respondents out of 21 answered that in their industry computers are use only el for accounting and administration department. The need for exercising control of the inventory by means of computer is of prime importance Es t particularly in a capital-scare country like Nepal. 194 Reference Target and Performance of Public Enterprises, Government of Nepal, Ministry of Finance, 2009. 2. Hetauda Cement Industry Ltd. (HCIL)- At A Glance. Published by Hetauda Cement Industry Ltd. 3. C. Paul Jannis, Carl H. Poedtke and Donald R Ziegler, Managing and Accounting for Inventories, A Ronald Press Publication, John Wiley and Sons.USA 1980, p. 64. 4. Vijaya Saradhi P. Sisthla, “Working Capital Management in Public Enterprise” International Centre for Public Enterprise in Developing Countries. Yugoslavia. (ICPE monograph No. 51, 1982, p. 51). 5. M. Chapman Findlay III and Edward E Williams, An Integrated Analysis for Managerial Finance, (New Jersey Prentice Hall Inc., 1970), P. 70. 6. I. M. Pandey, Financial Management. Vikash Publishing House Pvt. Ltd., P. 125. 7. James C. Van Horne and John M. Wachowicz, Jr., Fundamental of Financial Management, Prentice Hall of India Pvt. Ltd, New Delhi, 1997. 8. R Derbin Allen and Bierman Harold Jr., Managerial Accounting An Introduction, W. B. Saunders Company Philadelphia, 1975, P. 155. Es t el ar 1. 9. Eugene F. Brigham, Louis C. Gapenski, Michael C. Ehrhardt, Financial Management-Theory and Practice (9th edition), Harcourt Asia Pvt. Ltd., Harcourt Collage Publishers, P. 75. 10. Ibid. 11. I. M. Pandey, Financial Management. op. cit., P. 124. 12. Leopold A. Bernstein, Financial Statement Analysis: Theory, Application and Interpretation. (Illinois: Richard D. Irwin, Inc.,1978) P. 442; and John D. Martin, J. William Petty, Arthur J Keown and David F. Scott, Jr. Basic Financial Management. (New Jersey Prentice Hall Inc., 1979) P. 149. 13. Lawrence J. Gitman, Principle of Managerial Finance, New York: Harper and Row Publishers, 1989, P. 156. 14. MY Khan PK Jain., Financial Management –Text and Problem -2nd Edition. Tata McGra-Hill Publishing Company Limited, New Delhi. 15. James W. Prichard & Robert H. Eagle, “Modern Inventory Management” John Wiley and Sons, Inc, New York, 1965, P. 20. 195 V. K. Bhalla. Financial Management and Policy. Anmol Publication Pvt. Ltd., New Delhi, P. 380. 17. I. M. Pandey Financial Management, Vikas Publishing House Pvt. Ltd., 8th Edition, P. 32. 18. Buffa, E. S. and Taubert W. H. Production Inventory System-Planning and Control Homewood Illinois, Irwin 1972, p. 616. 19. Production and Inventory Control, Systems and Decisions. James H. Greene, Richard D. Irwin Inc. Homewood Illinois 1974 Irwin- Dorsey International London England, P. 213. 20. I. M. Pandey, Financial Management, op. cit., P. 130. 21. R. S. Chadda, Inventory Management in India. Allied Publishers’, New Pvt. Ltd., New Delhi, P. 12. 22. http://www.investorwords.com/11626/Gross_Margin_Return_On_Investment_G MROI.html#ixzz1YjtVMh45. Es t el ar 16. 196
© Copyright 2026 Paperzz