Die और Tool Procurement Errors (Visibility की कमी से Over-Buying/Under-Buying)
Definition
जब manual spreadsheet में inventory track होती है तो data stale होता है। Procurement officer को पता नहीं चलता कि कौन सी die पहले से 500 units stock में है। फिर फिर order दे देता है, या जब stock कम दिखता है तो rush order लगाता है। Rush orders में 20-30% extra freight/expedite charges होते हैं। साथ ही, wrong specification की tool order होती है (manual copying error), जो फिर scrap हो जाती है।
Key Findings
- Financial Impact: ₹20-35 लाख annually: (i) Over-inventory carrying cost: 30-40% excess stock × ₹500-1000/unit value × 1000-2000 SKUs (dies) = ₹15-25 लाख; (ii) Rush order premium: 10-15 rush orders/year × ₹50,000-100,000 expedite cost = ₹5-15 लाख; (iii) Tool specification errors/scrap: 5-10 wrong orders/year × ₹20,000-50,000/order = ₹1-5 लाख; (iv) Obsolete tool write-off: ₹2-3 लाख/year
- Frequency: Continuous (monthly procurement cycle); peak during seasonal demand swings
- Root Cause: No real-time inventory dashboard, manual forecasting, disconnected procurement system, lack of cross-functional visibility (production vs. warehouse), no ABC analysis automation
Why This Matters
The Pitch: भारतीय Packaging manufacturers को bad purchasing decisions से ₹20-35 लाख annually waste होता है (over-inventory holding cost + rush order premium + scrap)। Real-time inventory visibility से procurement accuracy 85-95% हो जाती है।
Affected Stakeholders
Procurement Manager, Inventory Planner, Production Scheduler, Finance (Budget tracking), Warehouse Manager
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Financial Impact
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Current Workarounds
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Methodology & Sources
Data collected via OSINT from regulatory filings, industry audits, and verified case studies.
Related Business Risks
Die और Tooling Inventory में Manual Tracking से Production Bottleneck
GST ITC Mismatch और Tool/Equipment Asset Tracking में Audit Failure Risk
Tooling Inventory Deterioration और Rework Cost (कमज़ोर Storage से)
Tool/Die Rental/Job Work Invoice Leakage (Manual Billing से Unbilled Tools)
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