🇮🇳India

अधिक इन्वेंटरी लागत और स्टोरेज व्यय (Excess Inventory Holding Costs)

3 verified sources

Definition

In manual Kanban environments, production teams lack real-time customer release visibility and forecast accuracy. To mitigate stockout risk, they hold higher safety stock across all process stages: (1) Raw materials (resins, pigments, additives) are over-ordered in bulk; (2) WIP queues accumulate as batches wait for Kanban signals; (3) Finished goods buffers are maintained to meet 'just-in-case' demand. Indian warehouse rental averages ₹15-25/sq.ft/month; mid-sized plants occupy 5,000-10,000 sq.ft for excess stock, costing ₹75,000-250,000/month in warehouse rent alone. Additionally, inventory carrying costs (obsolescence, spoilage of resin, temperature degradation) add 15-20% annually to inventory value.

Key Findings

  • Financial Impact: ₹75-150 lakhs annually. Breakdown: (1) Excess warehouse space: ₹75,000-150,000/month × 12 = ₹9-18 lakhs/year; (2) Inventory carrying costs (interest, insurance, spoilage): 15-20% of average inventory value. If average excess inventory = ₹50-75 lakhs, carrying cost = ₹7.5-15 lakhs/year. Total: ₹16.5-33 lakhs for large facilities; ₹75-150 lakhs for multi-facility operations.
  • Frequency: Ongoing; inventory accumulates continuously under manual Kanban.
  • Root Cause: Manual Kanban cards provide only backward signals (current need), not forward visibility (future demand). Production teams cannot distinguish between true demand and bullwhip effect. No integration with customer release schedules or ERP demand forecasts.

Why This Matters

The Pitch: Indian plastics plants waste ₹75-150 lakhs annually on excess inventory carrying costs due to poor demand visibility. Real-time e-Kanban systems reduce inventory by 30-40%, freeing up ₹30-60 lakhs in tied-up working capital and reducing storage costs by ₹20-40 lakhs/year.

Affected Stakeholders

Warehouse Manager, Inventory Planning, Finance/CFO, Supply Chain Manager

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Financial Impact

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

उत्पादन बाधा और मैनुअल कानबन प्रबंधन में विलंब (Production Bottleneck & Manual Kanban Delays)

₹50-100 lakhs per facility annually (15-25% capacity loss). Calculation: If a typical mid-sized plastics plant processes ₹5 crore annual revenue with 80% capacity utilization, manual delays reduce effective capacity by 15-25%, representing ₹75-125 lakhs lost revenue per year. Additional impact: 1-3 emergency rush orders per week (₹5,000-15,000 expediting cost per order) × 50 weeks = ₹2.5-7.5 lakhs annually in rush charges.

डेटा की कमी से खराब उत्पादन निर्णय और पूर्वानुमान त्रुटि (Poor Production Forecasting & Demand Visibility)

₹40-80 lakhs annually. Estimated via: (1) Rework due to grade errors: 2-4% of production volume × average margin loss = ₹15-30 lakhs/year; (2) Spoilage from over-production: 1-2% of annual production value = ₹5-10 lakhs/year; (3) Inefficient changeover costs due to wrong batch sizing: 15-20 changeovers/week × ₹10,000 cost per changeover = ₹78-104 lakhs/year. Conservative estimate (combined): ₹40-80 lakhs/year.

ग्राहक डिलीवरी विलंब और सेवा स्तर समझौता (Customer Delivery Delays & SLA Breaches)

₹30-60 lakhs annually. Calculation: (1) Lost orders due to delays: 5-10% of quarterly peak-season volume (estimate: ₹10-20 lakhs/quarter × 2 quarters = ₹20-40 lakhs/year); (2) SLA breach penalties: 2-5 penalty incidents per month × ₹5,000-10,000 per incident = ₹12-60 lakhs/year (depending on contract terms). Total: ₹30-60 lakhs/year for mid-to-large facilities.

GST आपूर्ति विलंब और ITC मिलान समस्याएं (GST Supply Delays & ITC Reconciliation Issues)

₹15-35 lakhs annually. Breakdown: (1) ITC dispute resolution: 10-20 flagged invoices/month × ₹50,000 cost per resolution (consultant fees, audit time) = ₹60-120 lakhs/year (high-risk cases); (2) GST demand notice payment (reverse charge): ₹5-10 lakhs in trapped GST on materials; (3) Audit penalty for improper ITC claim: 10-25% of wrongly claimed ITC (estimate: ₹5-15 lakhs if flagged). Conservative combined estimate: ₹15-35 lakhs/year.

स्क्रैप चोरी और अनधिकृत उपयोग

2-5% inventory shrinkage from poor tracking (industry standard)[2][5]

क्षमता हानि

Lost production from idle equipment; minimized by SPC (industry standard 5-10% capacity recovery)

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