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VARIETY
REDUCTION AS A TOOL FOR EFFECTIVE MATERIALS CONTROL
Abstract
This
research study is based on variety reduction as a tool for effective material
control, a case study of Nigeria Bottling Company Plc. To understand the
research work better, efforts was made at the introductory stage to explain the
general importance of variety reduction with special consideration being placed
on company especially Nigeria Bottling Company Plc, Kaduna. Also the general
problem was also emphasized on such non recognition of the role of variety
reduction on storage of different articles that can serve the same purpose.
Effort was also made to identify the purpose of the study such as the degree of
importance attached to variety reduction, areas covered by variety reduction
and its operational activities. It also focused on its significance to the
organization, the academics, the populace and the researcher. Research question
were also generated to determine the importance the organization placed on
variety reduction and how variety reduction facilitate the organization operational
efficiency. The survey research design is employed; also simple random sampling
procedure was employed. The researcher used questionnaire and documentary
sources. The likert four rating scale technique is used to analyze the data,
findings made among which are, that the organization considered variety
reduction to facilitate the organizational efficiency and that the variety
reduction minimizes cost and avoid storing the same item that can serve the
same purpose in making material available in the store. However, the researcher
summarized and concluded the research study and made recommendations to the
company, amongst which are formulation of variety reduction policy to align
with the vision and mission of the organization, always employed a competent
hand to handle variety reduction activities, to strive as much as possible to
create a variety reduction unit to be controlled by a qualified store manager,
purchasing and supply officer and engineer.
CHAPTER I:
Introduction
1.1 Background of the Study
Variety
reduction can be applied to any production process. The technique certainly has
more effect if applied in the right place and at the right time.
Apparently
in many organization, it is clearly to see organization be it manufacturing
holding different number of types, size or grade of a product that can perform
the same function, this means duplication of items, the cost of materials is
the last remaining cost that is truly variable, a reduction in the cost of
material clearly offers on usual opportunity for profit improvement, therefore
the need for purchasing to minimize
waste and enhance maximum services within the organization has resulted
in the use of variety reduction. Variety reduction can make a substantial
savings in inventory by standardizing and rationalizing the range of materials,
parts and component kept in store. Variety reduction can be achieved by using,
so far as possible, standardized components and subassemblies to make end
products that are dissimilar in appearance and performance so that variety of
final products uses only a few basic components, variety reduction can also be
applied when considering capital purchases, by ensuring compatibility with
existing machinery, the range of spares carried to ensure against breakdowns
can be substantially reduced also variety reduction can be undertaken
periodically to examine arrange of stock items to determine
the intended
use for each item of stock, how many stock item serve the same purpose, the
extent to which items having the same purpose can be gives a standard
description, what range of sizes is essential and lastly what items can be
eliminated all these are done to ensure effective material control. Therefore,
variety reduction can be defined as “the process of reducing the number of
types, size or grades of a product that are purchase made or stocked (Hassan
2008 p. 445).
1.2 Statement of Problems
Among the
objectives of all private sector is to maximize profit and reduce costs. These
objectives can be achieved in material control aspect of the organization by
imploring a strategy that will help or ensure that the number of types, sizes
or grades of a product held in the organization are not duplicated when
purchased, this will help in investing minimum cost on materials. But is quite
unfortunate that these objectives are rarely achieved as a result of non
recognition of the role of variety reduction in an organization as a tool for
effective material control.
Variety
reduction is the process used to describe standardization and simplification
where different items that are capable of performing the same function are
carried in large quantities, variety reduction is required but hardly did any
organization take cognizance of this vital function as a tool for effective
material control, as a result many organizations continue to hold materials,
parts, items that are similar and capable of performing the same function this
affect the material control unit of the organization efficiency be holding
excess stock.
Variety
reduction helps to reduce the number of varieties in the store, it also help to
stipulate suitability of purpose, reduce the stock held and its associated cost
another importance of variety reduction is to establish datum as a basis for
development, but despite all these importance of variety reduction to an
organization the researcher observed that most organization lost foresight of
this important function that required a proactive approach for better control
of materials held in an organization.
Also variety
reduction assist the organization in avoiding buying different types of item
that can serve the purpose, quicker and effective stock taking, reduce
obsolete, overhead cost, it also facilitate easier inspection due to product
uniformity and easier stock control and less storage space required, in view of
all these benefits of variety reduction to an organization, the researcher
observed that hardly can any organization show a unit or professionals bestowed
with the responsibility of performing this vital function as a result many of
these benefits are not derived by organizations.
1.3 Objectives of the Study
The purpose
of embarking on this research work by the researcher is to determine the effect
of variety reduction on materials control.
Specifically,
the research work is set out;
- To determine the areas
covered by variety reduction in an organization is, Nigeria Bottling Company
Plc Kaduna.
- To determine stages of variety reduction
that can facilitate the organization’s operational efficiency.
- To determine if the
benefit of variety reduction can minimize cost in the organization.
- To determine if the
reasons for variety reduction can improve quality production in the
organization.
- To determine why variety
reduction should be control through
the importance attached to variety reduction.
1.4 Significance of the Study
This study
will bring to light the effect of variety reduction on materials control in
Nigeria Bottling Company Plc Kaduna plant.
The study
will also be of great benefit to potential investors, those in academics, other
researcher in business management fields and the entire populace.
The
significance of the research work to the organization is to provide them with
relevant information on how important variety reduction is in facilitating
organizational efficiency, productivity and materials control and also to
change their orientation in terms of how best to manage, maintain and handle
their material or inventory level and this will also be applicable to other
industries that is into production activities.
The study
will also be of immense benefit to the potential investors, in the sense that
it will provide them with freehand information on how important variety
reduction is in promoting material flow. In the academics, the research work
can stand as a study material and reference book they can consult to broaden
their knowledge on what it meant by variety reduction.
The research
work will also serve as a reference book to the other researcher on this type
of project topic. To the entire populace, come across this research work, the
research work will provide them with the knowledge on how important variety
reduction is to an organization and it will also add value to their knowledge.
The research
work is embarked on by the researcher to broaden and ad value to his knowledge
on variety reduction on materials control.
Lastly, the
research work is also a requirement in fulfillment for the award of Higher
National Diploma in Purchasing and Supply Department of Kaduna Polytechnic.
1.5 Scope of the Study
This
research work is based on variety reduction as a tool for effective material
control. A case study of Nigeria Bottling Company Plc Kaduna plant which is
situated at Kaduna South industrial layout Kaduna, Kaduna State.
The
researcher intends to examine the extent to which variety reduction techniques
if applicable may lead to effective material controls in the organization.
The findings
of this research work will primarily base on the data collected from the staff
of the plant draw from the stores, design, production, suppliers and purchasing
and supply personnel of Nigeria Bottling Company Plc Kaduna Plant.
1.6 Research Questions
This study
will attempt to provide answers to the following research questions:
- What are the areas covered by variety
reduction?
- To what extent the stages of variety reduction facilitate the organization
operational efficiency?
- How the benefit of variety reduction
does minimizes cost in the organization?
- How do reasons for variety reduction
improve quality production in the organization?
- What importance does the organization
attach to variety reduction?
1.7 Definition of Terms
Material
Control: Is a key activity which covers a wide range of different tasks from
the moment the product is designed up to and including its final delivery.
Standardization:
Is a process of reducing the number of varieties stocked to a controlled
workable minimum.
Simplification:
Is the elimination of all labour and materials that are absolutely essentials
so that more effective production can be carried out.
Redundancy:
Is the excess over the normal holding of stock.
Surplus
Materials: Having more than what is required or necessary.
Variety
Reduction: Is the process of reducing the number of types, size or grades of a
product that are purchased, made or stocked.
Store: Is a
place where goods are kept upon onward delivery.
Suppliers:
Those that supply or makes material available to an organization when needed
and when required.
Value: Is
the cost from which the function of a product or service may be obtained or
accomplished at a form or place with the require quality.
Value
Engineering: This is simply the application of value technique to a ‘new’
product, process, components and system, commencing with the conceptual design
or prototype stage of the product.
Value
Analysis: Is a tool or technique for identifying unnecessary cost factors with
a view to eliminating or reducing them.
Cost: What
it takes to make or buy a certain material or product.
Organization:
Is the process of dividing work into convenient tasks or duties, by creating
and maintaining like-groups to achieve specific objectives.
Personnel:
The human resources and labour relations function.
Purchasing:
The buying of required equipments, materials and services.
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