the financial statement analysis and cost reduction program at tata motors ltd. by chetan aher

7/14/2019 The Financial Statement Analysis and Cost Reduction Program at Tata Motors Ltd. by Chetan Aher

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A

PROJECT REPORT ON

The Fina ncial Sta temen t Analysis and Cost

Reduction Program

AT

TATA MOTORS LIMITED,

PUNE

Submitted ToPune University

In Partial Fulfillment of the Requirement ofMaster of Business Administration

Submitted By

M r. Che tan G . Aher

M .B.A

Under the Guidance of

Prof . M r . M aheshHalale

THROUGHTHE DIRECTOR OF

Visahwakarma Institute of Management2005 - 2007


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The Financial Statement Analysis and Cost Reduction Program.

MBA Program 2005-2007 2

Acknowledgement

I hereby take the opportunity to express my gratitude towards those who have made great

contribution in completion of this project work. I feel immense pleasure to thanks

Mr. A.A.Phalke,Head of shared services Tata Motors, and Mr. D.N.KulkarniSen i o r

finance Manager of shared services, who very kindly helped me in providing necessary

information and guidance from time to time. Mr. Prabhakar Panchbhai, HR Manager

TataMotors , who has given me the opportunity to work with Tata Motors as project

trainee. I am immensely thankful to my external project guideMr. D.N.Kulkarni and

internal project guide Prof. Mahesh Halalewho has been a constant source of inspiration.

Both are them keen interest and encouraging guidance, which lead to completion of this

project in time, is hard to express in words. I will take the opportunity to convey my

thankfulness to ourDirector Prof. Dr.Mr. Sharad Joshi for his kind help and warm

treatment. This is place to express my gratitude towards them who have directly and

indirectly helped me and made my work enjoyable.


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ContentsChapter - 1 Introduction

1.1 TATA Motors Profile

1.2 Subsidiaries of TATA Motors

1.3 Milestone

1.4 Objective

1.5 Methodology Collection of Data

Chapter 22.1 Executive Summary of project

2.2 Financial Performance of company2005-2006

Chapter - 3 Financial Statement of analysis3.1 Meaning

3.2 Trend Analysis - Meaning

3.3 Reason for loss in 2000-2001

3.4 Ratio Analyses - Meaning3.5 Types of Ratio

3.6 Calculation & Analyses of Ratios

Chapter- 4 Cost Reduction Progamme4.1Cost Reduction process

4. 2 Cost reduction Programme of TATA Motors

Chapter- 55.1 Finding

5.2 Conclusion

5. 3 Bibliography


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Chapter 1

1.1TATA MOTORS Profile

1.2 Subsidiaries of Tata Motors

1.3 Milestone

1.4 Objective

1.5 Methodology Collection of data


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Company Profile

TATA Motors formerly known as TELCO (TATA engineering and LocomotiveCompany) fully integrated automobile manufacturer with a portfolio that covers trucks,

buses, utility vehicles and passenger cars, which is now being famous for giving. TELCO

is established in 1945. In July 2003 TELCO changed its name into TATA Motors

Ltd . TATA Motors Limited is India's largest automobile company, with revenues of US

$ 6.0 billion in 2005-06. TATA Motors is the leader in commercial vehicles in each

segment, and the second largest in the passenger vehicles market with winning products

in the compact, midsize car and utility vehicle segments. The company is the world's fifth

largest medium and heavy commercial vehicle manufacturer.

The company's 22,000 employees are guided by the vision to be best in the

manner in which we operate, best in the products we deliver, and best in our value

system and ethics.

TATA Motors' presence indeed cuts across the length and breadth of India. Over 3.5

million TATA vehicles ply on Indian roads, since the first rolled out in 1954. The

company's manufacturing base is spread across Jamshedpur, Pune and Lucknow, supported

by a nation-wide dealership; sales, services and spare parts network comprising about1,200 touch points.


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ABOUT THE VARIOUS PLANTS:

JAMSHEDPUR: Area: 700+ Acres - Strength: 14000

Oldest plant of Tata Motors.

Initially manufacturing Locomotive Engines.

Collaboration with Mercedes Benz.

Started production of Trucks and Bus Chassis.

Recently collaborated with M/s. Daewoo of Korea and manufacturing

Heavy Commercial Vehicles -Trucks/Buses/Tippers under the brand name

of Novas.

LUCKNOW: Area: 600 Acres Strength: 3500

Tata Sumo was initially assembled at Lucknow Plant.

Now the production of Sumo has been stopped and Trucks and Buses are

now manufactured/assembled at Lucknow.

The production is same as Jamshedpur. Except Daewoo collaboration

vehicles.

Lucknow plant is under the Head - Jamshedpur Plant.

DHARWAD: Area: Around 530 Acres

A big piece of land has acquired in Dharwad.

No plan finalized yet for any production/Assembly line.

PUNE: Area: 600 + 600 (Residential) Acres Strength: 12000

Flagship plant of Tata Motors.

Manufacturing various types of Heavy Commercial Vehicles, Medium

Commercial Vehicles, Light Commercial Vehicles-Tata Sumo, Tata Safari,

Mini truck ACE and indigenously developed Small Car - Indica, Indigo and

Marina.

CHINCHWAD: Area 325 Acres.

Casting & Aluminum Foundry as well as Tata Automation Ltd.


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CAR PLANT (PIMPRI): Area: 150 Acres Strength: 6500

Production ofSmall Car started in 1999.

Daily production at present is 750 Cars.

Tata Indica, Indigo and Marina are manufactured at Car Plant (K Block). It is

one of the ultra modern plants in India

Global Scenario:

The company's commercial and passenger vehicles are already being marketed in

several countries in Europe, Africa, the Middle East, Australia, South East Asia and South

Asia. It has assembly operations in Malaysia, Kenya, Bangladesh, Spain, Ukraine, Russia

and Senegal.

Tata Motors, the first company from India's engineering sector to be listed

in the New York Stock Exchange (September 2004), has also emerged as a global

automotive company.

In 2004, it acquired the Daewoo Commercial Vehicles Company, Korea's second

largest truck maker. The rechristened Tata Daewoo Commercial VehiclesCompany has already begun to launch new products.

In 2005, Tata Motors acquired a 21% stake in Hispano Carrocera, a reputed

Spanish bus and coach manufacturer, with an option to acquire the remaining stake

as well. Hispano's presence is being expanded in other markets.


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Subsidiaries

Through its subsidiaries, the company is engaged in engineering and automotive solutions,

construction equipment manufacturing, automotive vehicle components manufacturing and

supply chain activities, machine tools and factory automation solutions, high-precision

tooling and plastic and electronic components for automotive and computer applications,

and automotive retailing and service operations.

Over the years, Tata Motors has made substantial investments in building

companies that add value, facilitate and support its diverse range of business activities.

1) Telco Construction Equipment Co. Ltd. (Telcon)

2) Tata Technologies Ltd. (TTL) and Tata Technologies Ltd., USA (TTUS)

3) HV Axles Ltd. (HVAL)

4) HV Transmissions Ltd. (HVTL)

5) TAL Manufacturing Solutions Ltd. (TAL)

6) Sheba Properties Ltd. (Sheba)

7) Concorde Motors (India) Ltd. (Concorde) [formerly known as Minicar(India) Ltd.]

8) Tata Daewoo Commercial Vehicle Company Ltd (TDWCV)

9) Tata Motors Insurance Services Ltd. (TMISL) [formerly known asConcorde Motors Ltd.]

10)Tata Motors European Technical Centre plc


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MilestonesYear Particulars

1945 The establishment of Railway Engine factory in Jamshedpur.

1954

TATA collaborated with Daimler-Benz for developing commercial

vehicle. Launch of the first Tata Mercedes Benz Truck

1965The first TATA branded truck roll out.

Collaboration with Daimler Benz, Germany ends.

1977 The First Commercial Vehicle Manufactured at the Pune Plant

1986 First Light Commercial Vehicle from Telco, The Tata 407 is launched.

1991 The Millionth Tata Vehicle A million Indians are proud owners ofTata Vehicles.

1992Tata Estate Telco s Second passenger Vehicle launched.

To start third factory in Lucknow.

1994 TATA Sumo Moves with growing with faster growth.

1998 The First Tata Indica launched.

2003 Change in name From TELCO to TATA Motors Ltd.

2004-05 Tata Motors launches Branded buses and coaches under Globus and

Starbus brand name.

Tata Motors acquires 21 % stake in Hispano Carrocera SA, a well-

known international bus company.

Tata Motors listed its Depositary programme on the new York Stock

Exchange. It is the first Company in the Indian Engineering and

automobile sector to do so.


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Objectives

There are different objectives for which the study has been completed. They are as

follows:-

1) To Analysis the loss of TATA Motors in the year 2000-2001

2) To understand the importance of financial statement analysis, calculate the ratios,

and also analyze them.

3) To study the Tata motors financial position and market standing through the ratio

analysis

4) To study the Tata motors cost reduction programme.

5) To find out profitability, liquidity of Tata motors


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METHODOLOGY

The main objective of the study is to determine and analyze the financial position and

Cost reduction of the Tata Motors Ltd. For this purpose, the information was collected

by two ways:

1. Primary Data:

Primary data is that which is not published but it is very useful data.

So the information was collected by discussion held with the executives of accountsand

finance department.

2. Secondary Data:

Secondary data consist of the information that already exists or someone has

collected it for specific purpose. This data was collected by:

A) The company profile was collected from website of Tata Motors Ltd. (TML),

www.tatamotors.com

B) The other analytical information was collected from annual report and books and

discussion with finance manager.
http://www.tatamotors.com/


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Chapter 2

2.1 Executive summary of project report

2.2 Financial Performance of company in 2005-2006


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EXECUTIVE SUMMARY

A Tata motors, with revenues of over US $ 6.0 billion (FY 2005-06), is a flagship

company of the Tata group. It is the world s largest company of the Tata group, it is

world s largest medium and heavy commercial vehicles model with the range of light

vehicle manufacturer and producers more than range of light, medium to heavy duty

trucks, buses and tractor and trainers. Tata motor is the second largest player in the

domestic passenger car market in India. Two of its five passenger vehicle brands are

among top ten.

Income statements of the Tata motors for years 99-00 to 05-06 are the business

mirrors, which reflect the financial position and operating strength and weakness of the

concern. Income statement analysis which is done by using ratio analysis and trend

analysis give the true picture of the company during1999-2000 to2005-2006. Cost

reduction is the true medicine for the revival of the company during the decline of the

company which is studied in this project.

Year 2000-01which was the black year Tata motor s history, which suffered from huge

loss. It wasn t any one factor that fueled Tata engineering s fall. The market for

commercial vehicles, the core of the company s business.

Tata motor which was running thorough bad phase during the gestation period

preferred cost reduction which was the best terminology at India s largest automobile

company.

The cost reduction initiative, which began in April 2000, is arguably the most

important element in the remarkable revival that has seen the Tata motor recover from

the loss of Rs 28 crores in the first quarter 2002-2003.

A quality improvement program based on the six sigma model, and the other

components of this revival, but it is in the cost reduction that the gains have come

thickest and fastest.

The big positive of the cost reduction initiative goes beyond the statistics of money

saved. The crisis unified the company. Companies have emerged from this as phoenix.


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Financial Performance of company in 2005-2006

The company s financial performance continued to improve in this financial year

owing to a good volume growth of 13.7 % and continued efforts by the company to

maintain its margins, driven mainly by cost reduction efforts. The following points to be

noted down:

1) Sales Volume:This year was an outstanding year for the company, which recorded peak

performance on all major financial parameters. Overall sales volume at 454129 and

turnover at Rs. 24293.23 crores were higher at 14 % and 18 % respectively than previous

year 2004-05.

SALES VOLUME 2004-05 2005-06

CV 189993 214836

PV 179076 189070

EXPORTS 30497 50223

TOTAL 399566 454129

190 179

30

400

215

189

50

454

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

CV PV EXPORTS TOTAL

2004-05

2005-06


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2. SOURCES OF REVENUE:

Sales Turnover has increased by 18.8 % to another record high of Rs. 20891.31 croresfrom Rs. 17585.22 crores in 2004-05.

PARTICULARS 2004-05 % 2005-06 %

Domestic Vehicle Sales 17636.46 85.41 19649.29 80.88

Exports 1518.08 7.35 2395.34 9.86

Vehicle spare parts 783.46 3.79 984.74 4.05

Hire purchase 159.47 0.77 432.67 1.78

Dividend 166.09 0.80 289.11 1.19

Others 385.10 1.87 542.08 2.23

20648.66 100 24293.23 100

(9.86 %)

(4.05 %)

(80.88 %)

Domestic VehicleSALES

Exports

Vehicle Spare Parts

Hire Purchase

Dividend /OtherIncome

Others


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SALES TUROVER:

SALES TURNOVER 2004-05 2005-06 %CHANGE

VOLUME 399566 454129 13.66

VALUE (Crores) 20648.7 24293.2 17.65

360000

380000

400000

420000

440000

460000

18000

19000

20000

21000

22000

23000

24000

25000

VOLUME 399566 454129

VALUE 20648.66 24293.23

2004-05 2005-06

1) Manufacturing and other Expenses increased by 18.5 % to Rs. 18331.36 crores in

2005-06 from Rs. 15466.17 crores in 2004-05.2) Net raw material consumption increased by 18 % to 14632.65 crores in 2005-06 from

Rs. 12341.14 crores in 2004-05. This was largely a result of high steel prices during the

first quarter of the year and sharp increase in the prices of other commodities like

aluminium, copper and rubber. However the company manage to maintain its ratio of

net raw material consumption to net turnover at 701 % in 2005-06 on account of the on

going cost reduction programme. As a part of cost reduction programme, the company

initiated global sourcing, vendor rationalization and value engineering during 2005-06.

3) Employee cost increased by 10.00 % during the year to Rs. 1,143.13 crores from Rs.1039.34 Crores registered in the previous year . The company restructured the salaries

of its employees during the year to align the same to the industry standards. However,

increase in productivity helped the company reduce its employee cost as a percentage

of net turnover to 5.5 %, as compared to 5.9 % in 2004-05.


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4) Profit before depreciation interest, exceptional items and tax increased by 22.7 % to

Rs. 2337.18 crores in 2004-05. the margin increased to 13.7 % from 13.3 % in 2004-

05.

5) Depreciation for 2005-06 increased by 15.7 % to Rs. 520.94 crores from Rs. 450.16

crores in 2004-05 on a account of increase in fixed assets.

6) Net interest cost increased to Rs. 226.35 crores in 2005-06 from Rs. 154.15 crores in

2004-05. The increase in interest cost was on account of significant increase in

working capital requirement for vehicle financing business and hardening of interest

rates during the year. The company also issued foreign currency convertible Notes

aggregating to JPY 11.76 Billion during 2005-06.

7) Profit After Tax of the company increased by 24.3 % to Rs. 2053.38 Crores from Rs.

1651.90 crores in 2004-05.

8) Earning per share increased by 18 % to Rs. 40.57 as compared to Rs. 34.38 last year.

9) Balance sheet size of the company increased to Rs. 9096.45 crores in 2005-06 from Rs.

7172.09 crores in 2004-05. this increase in attributed to significant capital expenditure

insured by the company for its new product introduction programme and substantial

increase in our vehicle financing business.

10)As on 31stmarch 2006, the ordinary shares Capital of the company stood at Rs. 382.87

crores as compared to Rs. 361.79 crores as on 31st March 2005. this was on account of

allotment of ordinary shares of the company to the shareholders of the erstwhile Tata

Finance Limited consequent upon its amalgamation with the company and the

conversion of 1 % convertible Notes ( USD 100million due 2008 ) to the extent of 91.4

% and the zero coupon Convertible Notes ( USD 100 mn due 2009 ) to the extent of

81.9 % during the year.

11)Gross Debt stood at Rs. 2936.84 crores as on March 31St 2006 as compared to Rs.

2495.42 crores as on 31st

march 2005.

12)Fixed assets of the company increased to Rs. 4521.23 Crores in 2005-06 from Rs.3696.51 crores in 2004-05. This is largely on account of additional capacity set up for

manufacturing Tata Ace during the year, product development expenditure for the on

going new product development programme.

13)Investment of the company reduced to Rs. 2015.15 crores in 2005-06 from Rs. 2912.12

crores in 2004-05 to fund the capital expenditure and the vehicle financing operations

during the year.


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14)Net current Asset of the company increased to Rs. 2545.95 crores in 2005-06 from Rs.

545.36 crores in 2004-05. this increase is on account of vehicle financing loans and

advances increasing to Rs. 4582.80 crores in 2005-06 from Rs. 1583.80 crores in 2004-

05 and increase in inventories to Rs. 2012.24 crores in 2005-06.

15)The cash generated from operations before working capital changes and before

considering the development in the vehicle financing business was Rs. 2536.60 crores

as compared to the previous year figures of Rs. 2092.73 crores.

16)During the year under review, the company expanded its vehicle financing business

significantly with the merger of TATA Finance Limited, effective from 1st April 2005

and Rs. 1995.80 crores of Cash generated from operation was used in this business.


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Chapter - 3Financial statement of analysis

3.1Trend analysis

3.2 Reason for loss in 2000-2001

3.3 Ratio analysis

3.4Theoretical part of Ratio Analysis

3.5 Meaning and Graphical Representations of Ratio


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Financial Statement Analyses

The term financial statements are used in business refers to two

statement the balance sheet or statement of financial position reflecting the assets,

liabilities, capital and reserve as on a particular date and income statement or profit and

loss statement showing the results achieved during a certain period which are prepared at

the end of accounting period for a business enterprises. Financial statement also called, as

financial reports are account balances arranged in effective and meaningful order so that

the facts and concepts they portray may be readily interpreted and used as bases for

decision by all who are interested in the affairs of business.

The purpose of preparing financial statement is to convey to owners,

creditors and the general public about the financial position of the enterprises. Financial

statement used by the management as the basis for decision making, planning operations

like procurement of adequate financial and as a means exercising control over financial

position of the business and efficient and profitable use of assets.

According to American institute of certified public Accounts the

financial statement have been declared to process the following nature: the financial

statements are prepared for the purpose of presenting a periodical reviews or report on the

progress by the managements and deal with the status of investment in the business and

results achieved during the period under review. They reflect a combination of recorded

facts; accounting conventions applied affect them materially.

THE USEFULNESS OF FINANCIAL STATEMENT

The usefulness statement is the business mirror, which reflect the

financial position and operating strength and weakness of the concern. These statements

are useful to management, investors, bankers, workers, and government and public at

large.

The major uses of financial statements are:

As a report of stewardship.

As a basis of fiscal policies.

As a basis of granting credit.


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As an information to prospective investors.

As a basis for price

As an aid government

As a basis for taxation.

USES AND OBJECTIVE OF FINANCIAL STATEMENT ANALYSIS

Financial Statement Analysis seeks to spotlight the significant facts

and relationship concerning managerial performance, corporate efficiency, financial

strength & weakness and credit worthiness of the company. With the help of the financial

analysis the manager can rationlise his decision and reach the business goal easily.

TOOLS AND TECHNIQUES OF FINANCIAL STATEMENT

ANALYSIS

The analysis of financial statement consists of a study of relationship

and trends to determine whether or not the financial position and results of operating as

well as the financial progress of the company are satisfactory or unsatisfactory. The

analysis of facts

And related data was important and a number of techniques of analysis are:

1) Comparative statement

2) Common size statement

3) Trend analysis

4) Fund flow analysis

5) Ratio analysis


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COMPARATIVE STATEMENT

Comparative financial statements are those statements, which have

been designed in a way to provide time perspective to the consideration of various

elements of financial position embodied in such a statements. This is done to make the

financial data more meaningful. The statements of two or more years are prepared to show

absolute data of more years, increase or decreases in absolute data and in terms of

percentages.

Advantages:

These statements have some advantages. They summarized as under.

a) Inter period and/or firm comparison, are very much facilitated by such comparativestatement.

b) These statements are highlights upon the trends in a number of accounting

variables relating to performance and financial position.

c) With the help of comparative statements weakness in the operating cycle, financial

health, etc can easily identify and suitable remedial steps may be taken.

COMMON SIZE STATEMENT

In the comparative financial statements it is difficult to comprehend

the changes over the years in the relation to total assets, total liabilities and capital or total

net sales. Because of this limitation, it is impossible to make comparison between two or

more firms of an industry. The reason is that there is no common base of comparison of

absolute figures. Hence in common base for comparison is provided common size income

statement.

A statement in which balance sheet items are expressed as the ratio

of each asset and the ratio of each liabilities are called common size balance sheet. The

common size income statement, which established relationship between sales and other

items in income statement, which established the relationship between sales and other

items in income statement and this relationship, is helpful in evaluation operational

activities of the enterprise.


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TREND ANALYSIS

Trend percentage is immensely helpful in making a comparative

study of the financial statements for several years. Trend in general term signifies a

tendency. In other words the reviews and appraisal of tendency in accounting variables are

nothing but trends analysis. Such an analysis of business facts is very significant from the

point of view of forecasting or budget. Analysis of the trend in business facts may be made

in by calculating the trend ratio or percentage or by plotting points on a graphs paper or

chart. Trend analysis is calculated only for some important items, which can be logically

connected with each other. Unless the figure is connected with each other figures they are

not as much meaningful.

For example, trend analysis for sales, though shows a clear-cut increasing or decreasing

tendency. Becomes meaningful in the real sense when it is compared.

The following Trend analyses of balance sheet and profit

and loss A/c

Trend analyses of profit and loss a/c

Profit and loss a/c 1999-2000 2000-01 2001-02 2002-03 2003-04 2004-05

INCOMESALE OF PRODUCT ANDOTHER INCOME 100 91.08 99.49 121.1 173.51

230.37

LESS- EXICSE DUTY 100 86.88 93.41 117.25 152.65 205.98

EXPENDITURE

Mfg.& other Cost 100 91.48 97.62 95.39 135.11 182.68

Exps.TRANSFERRED TOCAPITAL A/C 100 49.57 63.83 69.05 .94

124.64


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Trend analysis of balance sheet 1999-2000 to 2004-2005

YEAR

1999-

2000

2000-

2001

2001-

2002.

2002--

2003

2003-

2004 2004-2005

SOURCES OF FUNDS

1.SHARE HOLDERS FUNDS(a) CAPITAL 100 100 124.97 124.71 139.44 141.37

(b) RESERVES & SURPLUS 100 85.69 61.32 65.09 92.52 107.18

SHARE HOLDERS FUNDS 100 86.67 65.66 69.18 95.72 109.51

2.LOAN FUNDS

(a) SECURED 100 109.88 81.48 62.85 57.12 29.68

(b) UNSECURED 100 87.55 71.11 31.09 23.42 148.12

LOAN FUNDS 100 99.82 76.81 48.54 41.93 83.06

3.DEFERRED TAX LIBILITIES ( NET) 100 - - 105.3 514.15 565.28

3.TOTAL FUNDS EMPLOYED 100 92.51 70.61 61.56 79.41 106.12

APPLICATION OF FUNDS

4.FIXED ASSETS

(a) GROSS BLOCK 100 104.01 106.43 108.11 110.42 121.98

(b) Less DEPRICIATION 100 114.35 133.01 148.25 165.39 188.94

(c) NET BLOCK 100 98.75 92.91 87.67 82.44 87.9

(d) CAPITAL WORK IN PROGRESS 100 70.5 35.86 40.04 73 137.49

100 95.97 87.3 82.99 81.51 92.78

5.INVESTMENT 100 115.52 99.09 99.6 254.57 242.52

6.DEFERRED TAX ASSET ( NET) 100 - 95 - - -

7.CURRENT ASSETS, LOAN AND ADVANCES(a) INTEREST ACCRUED ON INVESSTMENT 100 100 100 - - 6.12

(b)INVENTORIES 100 111.52 99.66 116.99 115.8 161.61

(C ) SUNDRY DEBTORS 100 84.99 90.6 106.58 69.28 91.61

(d) CASH AND BANK BALANCES 100 176.89 500.29 375.9 1180.46 91.4

(e) LOAN AND ADVANCES 100 73.09 59.05 62.28 107.48 3071.91

CURRENT ASSETS, LOAN AND ADVANCES 100 91.41 91.12 99.96 122.14 236.18

8.CURRENT LIABILITIES AND PROVISIONS

(a) CURRENT LIABILITIES 100 123.18 128.92 158.71 213.38 276.55

(b) PROVISIONS 100 68.23 75.22 121.66 165.85 433.68

CURRENT LIABILITIES AND PROVISIONS 100 116.81 122.69 154.41 207.87 294.77

9.NET CURENT ASSETS 100 19.07 1.21 55.11 121.99 69.35

10. MISC. EXPENDITURE 100 113.3 - 11.63 2.81 2.3

11. TOTAL ASSETS 100 92.21 70.61 61.56 79.41 106.12


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REASON FOR LOSS

1. Decrease in sales: -

With the help of Trend Analyses, we come to know that the sales is decrease by8.92% in the year 200-2001 (in the year 1999-2000) i.e. 100 %

( as base year) and it is 91.08% in year 2000-2001.

2. Increase in loan (secured loan): -

In the year 2000-2001 company took extra loan i.e.9.88% and

because of this they had to paid extras interest and hence loss increase

3. Increase in miscellaneous expenses: -

If we considered in 1999-2000 the miscellaneous expenses were

100%, the next year 2000-2001 was 113.30%.

For the help of trend analyses we can see that miscellaneous expenses also

increased by 13.30% it was another reason for losses.


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Ratio analysis

Introduction

The financial statement i.e. the income statement, the balance sheet. The

income statement, the statement of retained and the statement of changes in financial

position report what has actually happened to earnings during a specified period. The

balance sheet presents a summary of financial position of the company at a given point of

time. The statement of retained earnings reconciles income earned during the year and any

dividends distributed with the change in retained earnings between the start and end of the

financial year under study. The statement of changes in financial position provides a

summary of funds flow during the period of financial statement.

A ratio analysis is a very powerful analytical tool for measuring

performance of an organization. The ratio analyses concentrates on inter-relationship

among the figures appearing in the aforementioned four financial statements. The ratio

analysis helps the management to analyses the past performance of the firm and to make

further projection. Ratio analysis allows interested parties like shareholder, investors,

creditors, Government and analysts to make an evaluation of certain aspects of a firm s

performance.

Ratio analysis is a process of comparison of one figure against another,

which make a ratio and the appraisal of the ratios to make proper analyses about the

strength and weakness of the firms operations. The calculation of ratios is a relatively easy

and simple task but the proper analyses and interpretation of the ratios can be made only

by the skilled analyst. While interpreting the financial information, the analyst has to be

careful in limitations imposed by the accounting concepts and methods of valuation.

Information of non-financial nature will also be taken into consideration before a

meaningful analyses is made.

Ratio analysis is extremely helpful in providing valuable insight into a company s

financial picture. Ratios normally pinpoint a business strength and weakness in two ways:

Ratios provide an easy way to compare today performance with past

Ratios depict the areas in which a particular business is competitively advantaged

or disadvantages through comparing ratios to those of other business of the same

size within the same industry.


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CLASSIFICATION OF RATIOS

Ratio may be classified in a number of ways keeping in view the particular

purpose. Ratio indicating profitability is calculated on the basis of the profit and loss A/

C; those indicating financial are computed on the basis of balance sheet. To achieve

analysis effective understanding of the profitability and financial position of business, ratio

may be classified as:

A) LIQUIDITY RATIO:

The short-term liquidity ratio, which measures the liquidity of the firm and its

ability to meet it maturing short term obligations. Liquidity is defined as the ability to

realize value in money, the most liquid of assets. It refers to the ability to pay n cash, theobligations that are due. Following are the main types of the liquidity ratio.

1) Current Ratio

2) Quick Ratio`

3) Net-Working Capital Ratio

B) LEVERAGE RATIO:

The long-term financial stability of the firm may be consider upon its ability to meet

all its liabilities, including those not currently payable. The ratios which are important in

measuring the long term solvency ratio are as follows:-

1) Total Debt to Equity Ratio

2) Debt to total Capital Ratio

3) Interest Coverage Ratio

C) PROFITABILITY RATIO:

The purpose of study and analysis of profitability ratios are to help assess the adequacy

of profits earned by the company and also to discover weather the Profitability is

increasing or declining. The profitability of the firm is the net result of a large number

of the policies and decisions. The profitability ratios show the combined effects of

liquidity, asset management and debt management on operating results. Profitability

ratios are measured with reference to sales, capital employed, total assets employed,

shareholders fund etc. The major profitability rates are as follows:-


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1) Ebit To Sales Ratio

2) Eat To Sales

3) Working Capital To Net Assets

4) Return On Capital

D) TURNOVER RATIO:

Activity ratio or turnover ratio measure how effectively the firm employs itsresources.

These ratios are called turnover ratios which involve comparison between the level of

sales and investment in various accounts inventories, debtors, fixed assets, etc, activity

ratios are used to measure the speed with which various accounts are converted into sales

or cash. The following activity ratios are calculated for analysis.

1) Inventory Ratio

2) Fixed Assets Turnover Ratio

3) Fixed Assets Turnover Ratio

4) Debtors Turnover Ratio

5) Debtor Collection Period


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Meaning and Graphically Representation of Each Types of Ratio

1)Current ratio-:

This ratio measures the solvency of the company in the short term.Current assets are those assets, which can be converted in to cash within a year. Current

liabilities and provision are those liabilities that are payable within a year. A current ratio

2:1 indicates a highly solvent position. Banks consider a current ratio 1.33:1 as the

minimum acceptable level for providing working capital finance. The constituents of the

current assets are as important as the current assets themselves for evaluation of a company

solvency position.

A very high current ratio will have adverse impact on the

profitability of the origination. A high current ratio may be due to the pilling up of

inventory, inefficiency in collection of debtors, high balances in cash and bank A/C. proper

investment. The formula of ratio is=

Current Assets loan & advances

Current liabilities & provision

Year Current Asset Current Liabilities Current Ratio

1999-2000 3025.61 2239.3 1.352000-2001 2765.8 2615.8 1.057

2001-2002 2757.13 2747.61 1.003

2002-2003 3024.54 3457.88 0.87

2003-2004 3695.7 4654.94 0.79

2004-2005 7146.19 6600.83 1.08

2005-2006 9661.31 7115.36 1.36


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1.35

1.0571.003

0.870.79

1.08

1.36

0

2000

4000

6000

8000

10000

12000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.2

0.4

0.6

0.8

11.2

1.4

1.6

CURRENT ASSET CURRRNT LIABILITIES CURRENT RATIO

2. Quick Ratio & Liquid Ratio: -Quick ratio is used, as a measure of the company s ability to meet is

current obligation. Since BOD is secured by the inventories. The other current assets must

be sufficient to meet other current liabilities. A quick ratio of 1:1 indicates highly solvent

position. This ratio is also called acid test ratio. This ratio serves as a supplement to the

current ratio in analyzing liquidity. The formula of ratio is=

Current Assets - Inventories

Current liabilities BOD

Year Current Asset-stock Current Liabilities Quick Ratio

1999-2000 3025.61 - 990.56 2239.30 0.90

2000-2001 2765.80 - 1105.10 2615.80 0.63

2001-2002 2757.13 - 987.51 2747.61 0.64

2002-2003 3024.54 - 1159.29 3457.88 0.53

2003-2004 3695.70 - 1147.44 4654.95 0.54

2004-2005 7146.19 - 1601.36 6600.83 0.842005-2006 9661.31-2012.24 7115.36 1.075


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0.

91

0.6

3

0.

64

0.5

4

0.

559

0

.84

1.

075

0

1000

2000

3000

4000

5000

60007000

8000

9000

1999-

00

2000-

01

2001-

02

2002-

03

2003-

04

2004-

05

2005-

06

0

0.2

0.4

0.6

0.8

1

1.2

CURRET ASSETS CURENT LIABILITIES CURRENT RATIO

3. Debt Equity Ratios: -Capital is derived from two sources shares and loans. It is quite

likely for only shares to be issued when the company is formed but loans are invariably

raised at some later date. There are numerous reasons for issuing loan capital. The formula

of ratio is =

Long Term Debt

Shareholders funds

The ratio indicates the relationship between loan funds and net worth of the company,

which is known as gearing. If the proportion of debt to equity is low, a company is said to

be low geared, and vice versa. A debt equity ratio of 2:1 is the norm accepted by financial

institutions for financing of projects. Higher debt- equity ratio may be permitted for highly

capital intensive industries like petrochemicals, fertilizers, powers etc. the higher the

gearing, the more volatile the return to the shareholders.

A debt equity ratio, which shows a declines trend over the years, is

usually taken as a positive sign reflecting on increased cash accrual and debt and debt

repayment in act, one of the indicatory a unit turning sick is a risky debt equity ratio.

Usually when calculating ratio, the preference share capital is excluded from debt, but if

the ratio is show effect of use of fixed interest sources on earnings available to the


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shareholders then it is to be included. On the other hand, if the ratio is to examine

financial solvency then preference shares shall from party of the capital.

Year Total Debt Owners Equity Debt Equity Ratio

1999-2000 3004.26 3754.12 0.802000-2001 2998.88 3253.78 0.92

2001-2002 2307.72 2465.06 0.94

2002-2003 1458.31 2597.16 0.56

2003-2004 1259.77 3593.6 0.35

2004-2005 2495.42 4111.39 0.61

2005-2006 2936.84 5537.07 0.53

0.8

0.92 0.94

0.56

0.35

0.61

0.53

0

1000

2000

3000

4000

5000

6000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

TOTAL DEBT OWNERS EQUITY DEBT EQUITY RATIO

4. Shareholders equity Ratio: -It is assumed that larger the proportion of the shareholders equity, the

stronger is the financial position of the firm. This ratio will supplement the debt-equity

ratio. In this ratio the relationship is the establishment between the shareholders funds and

the total assets. Shareholders funds represents both equity and preference capital plus

reserves and surplus less losses a reduction in shareholders equity signaling the over

dependence on the outsiders for the long term financial needs and this carriers the risk of

the higher levels of gearing. This ratio indicates that the degree to which unsecured

creditors are protected against loss in the event of liquidation.


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The formula of ratio is =

Shareholders equity

Total asset

Year Share Holders

EquityTotal Assets(Tangible)

Share Holders

Equity Ratio

1999-2000 3754.12 8210.5 0.45

2000-2001 3253.78 7976.58 0.40

2001-2002 2465.06 7425.39 0.33

2002-2003 2597.16 7527.1 0.34

2003-2004 3593.60 10000.27 0.35

2004-2005 411.39 13754.76 0.29

2005-2006 5537.07 16197.69 0.34

0.45

0.4

0.33 0.340.35

0.29

0.34

0

20004000

6000

8000

10000

12000

14000

16000

18000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

SHARE HOLDERS EQUITY TOTAL ASSETS

SHARE HOLDERS EQUITY RATIO


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5) Interest coverage Ratio: -The interest coverage ratio shows how many times interest charges are covered by funds

that are available for payment of interest. An interest cover 2:1 is considered reasonable by

financial institution. A very high ratio indicates that the firm is conservative in using debt

and a very low ratio indicates excessive use of debt. The formula of ratio is=

Profit before interest depreciation & tax

Interest

The inventory turnover ratio measures hoe many times a company

inventory has been sold during the year. If the inventory turnover ratio has decreased from

past, it means that either inventory is growing or sales are dropping. In addition to that, if a

firm has a turnover that is slower than for its industry, then there may be obsolete goods on

hand, or inventory turnover has impact on the liquidity of the business.

Year Profit Before Int,Tax& Dep

Interest Interest Coverage

Ratio

1999-2000 345.60 404.74 0.85

2000-2001 497.87 443.58 1.12

2001-2002 763.35 382.23 2.1

2002-2003 1157.45 278.95 4.14

2003-2004 1940.70 161.26 12.03

2004-2005 2337.18 154.15 15.16

2005-2006 2868.8 226.35 12.67

0.85 1.122.1

4.14

12.03

15.16

12.67

0

500

1000

1500

2000

2500

3000

3500

1999-2000 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-2006

0

2

4

6

8

10

12

14

16

PROFIT BEFORE INT,TAX & DEPINTERESTINTEREST COVERAGE RATIO


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6) Total debt total assets: -This ratio measures the extent to which borrowed fund support the

firm s assets. The formula of ratio is=

Total debtTotal Assets

Year Total Debt Total Assets Total Debt AssetsRatio

1999-2000 3004.26 6758.38 0.44

2000-2001 2998.88 6252.66 0.48

2001-2002 2307.72 4772.78 0.48

2002-2003 1458.31 4160.77 0.35

2003-2004 1259.77 5367.52 0.23

2004-2005 2495.42 7172.09 0.35

2005-2006 2936.84 9096.45 0.32

0.440.48 0.48

0.35

0.23

0.350.32

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.1

0.2

0.3

0.4

0.5

0.6

TOTAL DEBT

TOTAL ASSETS

TOTAL DEBT ASSETS RATIO


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7) EBIT to Sales: -

The ratio is designed to focus attention on the profit margin arising

from business operations before interest and is deducted. The convention is to express

profit after tax and interest as a percentage of sales.

This ratio reflects net profit margin on the total sales after deducting

all expenses but before deducting interest and taxation. This ratio measures the efficiency

of operation of the company. The net profit is arrived at from gross profit after deducting

administration, selling and distribution expenses. The non operating incomes and expenses

are ignored in computation of net profit before tax, depreciation and interest. The formula

of ratio is=

Net profit before interest and tax 100Sales

Year EBIT Sales EBIt To Sales

1999-2000 345.60 7475.8 4%

2000-2001 497.87 6871.98 7.24%

2001-2002 763.35 7528.77 10.14%

2002-2003 1157.45 9111.26 12.70%

2003-2004 1940.70 13282.12 14.6%

2004-2005 2337.18 17585.22 13.29%

2005-2006 2868.8 20891.31 13.73%

4%

7.24%

10.14%

12.70%

14.60%13.29%13.73%

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0%

2%

4%

6%

8%

10%

12%

14%

16%

EBIT SALES EBIT TO SALES


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7) Working capital to net Sales:This ratio calculated by the following way

= Working capitalSales

Year Working Capital Net Sales Net WorkingCapital Ratio

1999-2000 786.31 7475.8 0.10

2000-2001 150 8164.22 0.01

2001-2002 9.52 7528.77 0.001

2002-2003 433.34 9111.26 0.04

2003-2004 959.24 13282.12 0.07

2004-2005 545.36 17585.22 0.03

2005-2006 2545.95 20891.31 0.12

0.1

0.01

0.001

0.04

0.07

0.03

0.12

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

WORKING CAPITAL NET SALES NET WORKING CAPITAL RATIO

9) Return on capital employed: -

The strategic aim of business enterprises is to earn a return on

capital. If any particular case, the return in the long run is not satisfactory, then thedeficiency should be corrected or the activity be abandoned for a more favorable one. The

rate of return on investment is determined by dividing net profit or income by the capital

employed or investment made to achieve that profit.

ROCE consists of two components i.e.

I) Profit margin. II) Investment turnover.


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It will be seen from the following formula that ROCE can be improved by

increasing one or both of its components i.e. the profit margin and the investment

turnover in any of the following ways:

- Increasing the profit margin

- Increasing the investment turnover

- Increasing both profit margin and investment turnover.

Return on investment analyses provides a strong incentive for optimal utilisation of the

assets of the company. This encourages managers to obtain assets that will provide a

satisfactory return on investment. The formula of ratio is=

Earning after Tax

Total funds employed

Year EAT Total FundsEmployed

Return On CapitalEmployed

1999-2000 71.20 6758.38 0.010

2000-2001 -500.34 6252.66 -0.08

2001-2002 -53.73 4772.78 -0.01

2002-2003 300.11 4160.77 0.072

2003-2004 810.34 5367.52 0.15

2004-2005 1236.95 7172.09 0.17

2005-2006 1528.88 9096.45 0.16

0.01

-0.08

-0.01

0.072

0.150.17

0.16

-2000

0

2000

4000

6000

8000

10000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006-0.1

-0.05

0

0.05

0.1

0.15

0.2

EAT

TOTAL FUNDS EMPLOYED

RETURN ON CAPITAL EMPLOYED


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10) EAT TO SALES:

This ratio shows the earning left for shareholders (both equity and

preference) as a percentage of net sales. It measures the overall efficiency of production,

administration, selling, financing, pricing and tax management. Jointly considered, EBIT

& EAT Ratio provide a valuable understanding of the cost and profit structure of the firm

and enable analyst to identify the source of business efficiency / inefficiency. The formula

of ratio is=

EARNIG AFTER TAX

NET SALES

Year EATNet Sales

EAT To Sales Ratio

1999-2000 71.2. 7475.8 0.95

2000-2001 -500.34 6871.98 -7.28

2001-2002 -53.73 7528.77 -0.71

2002-2003 300.11 9111.26 3.29

2003-2004 810.34 13282.12 6.10

2004-2005 1236.95 17585.22 7.03

2005-2006 1528.88 20891.31 7.32

0.95

-7.28

-0.71

3.29

6.17.03 7.32

-5000

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

-10

-8

-6

-4

-2

0

2

4

6

8

10

EAT NET SALES EAT TO SALES RATIO


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10) Inventory Turnover ratio:

Inventory turnover ratio measures how many times the companies

inventory has been sold. A considerable amount of a company capital may be tied up in the

financing of raw materials, work-in-progress and finished goods. It is important to ensure

that the level of stock is kept as low as possible, consistent with the need to fulfill

customers order in time. The formula of ratio is= Sales

Average Inventory

Year Sales Average Inventories Inventories Turnover

Ratio

1999-2000 7475.8 957.17 7.81

2000-2001 6871.98 1047.98 6.56

2001-2002 7528.77 1046.30 7.20

2002-2003 9111.26 1073.40 8.49

2003-2004 13282.12 1153.36 11.52

2004-2005 17585.22 1374.4 12.79

2005-2006 20891.31 1806.80 11.56

7.816.56

7.28.49

11.5212.79

11.56

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

2

4

6

8

10

12

14

SALES

AVERAGE INVENTORI


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12) Fixed assets turnover ratio:-This ratio will be analyses further with ratios for each main category

of assets. This is a difficult set of ratios to interpret as asset values are based on historic

cost .An increase in the fixed figure may result from the replacement of an asset at

increased price or the purchase of an additional asset intended to increases production

capacity. The ratio of the accumulated depreciation provision to the total of fixed asset at

cost might be used as an indicator of the average age of the assets; particularly when

depreciation rates are noted in the accounts. The formula of ratio is=

Sales

Average Fixed Assets

Year Sales Fixed Assets Fixed Assets To

Turnover Ratio

1999-2000 7475.8 3984.15 1.87

2000-2001 6871.98 3823.60 1.79

2001-2002 7528.77 3478.34 2.16

2002-2003 9111.26 3306.58 2.75

2003-2004 13282.12 3247.80 4.08

2004-2005 17585.22 3696.51 2.45

2005-2006 20891.31 4521.23 4.62

1.87 1.79

2.16

2.75

4.08

2.45

4.62

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.5

1

1.5

2

2.5

3

3.54

4.5

5

SALES FIXED ASSETS FIXED ASSETS TO TURNOVER RATIO


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13) Total assets turnover ratio: -

This ratio indicates the number of times total assets are being turned over in a year. The

formula of ratio is= Sales

Average Total Assets

The higher the ratio indicates overtrading of total assets while a low ratio indicates idle

capacity.

Year Sales total asset total assets turnoverratio

1999-2000 7475.8 6982.28 1.07

2000-2001 6871.98 6505.52 1.06

2001-2002 7528.77 5512.72 1.37

2002-2003 9111.26 4466.775 2.042003-2004 13282.12 4764.145 2.79

2004-2005 17585.22 6269.805 2.80

2005-2006 20891.31 8134.27 2.57

1.07 1.06

1.37

2.04

2.79 2.8

2.57

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

0.5

1

1.5

2

2.5

3

SALES TOTAL ASSET TOTAL ASSETE TURNOVER RATIO


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14) Debtor turnover ratio: -

Debtor turnover, which measures whether the amount of resources

tied up in debtors, is reasonable and whether the company has been efficient in converting

debtors into cash. The formula is; = sales

Avg. Debtors

Year Credit Sales Avg, Debtors Debtor Turnover Ratio

1999-2000 7475.8 1220.615 6.12

2000-2001 8164.22 821.055 8.37

2001-2002 7528.77 779.345 9.66

2002-2003 9111.260 875.165 10.41

2003-2004 13282.12 780.545 17.02

2004-2005 17585.22 713.155 24.66

2005-2006 20891.31 1527.1 13.68

6.12

8.379.66

10.41

17.02

24.66

13.68

0

5000

10000

15000

20000

25000

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

0

5

10

15

20

25

30

CREDIT SALES AVG DEBTORS DEBTOR TURNOVER RATIO


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15) Debtor s collection period: -Debtor s collection period, which measures how long it take to collect

amount from debtors. The actual collection period can be compared with the stated creditterms of the company. If it is longer than those terms, then this indicates some

insufficiency in the procedure for collecting debts. The formula is; =

Average Debtors 365Credit sales

Year Average Debtors Average CreditSales

Debtor Collection

Period

2000-2001 821.055 18.82 44

2001-2002 779.345 20.62 38

2002-2003 875.165 24.96 35

2003-2004 780.545 36.38 21

2004-2005 713.155 48.17 15

2005-2006 1527.1 57.23 13

1.1.1.1 4438

3 5

2 11 5 1 3

02 0 04 0 06 0 08 0 0

1 0 0 01 2 0 01 4 0 01 6 0 01 8 0 0

2 0 0 0 -

2 0 0 1

2 0 0 1 -

2 0 0 2

2 0 0 2 -

2 0 0 3

2 0 0 3 -

2 0 0 4

2 0 0 4 -

2 0 0 5

2 0 0 5 -

2 0 0 6

0

10

20

30

40

50

A V E R A G E D E B T O R S

A V E R A G E C R E D I T S A L E S

D E B T O R C O L L E C T IO N P E R I O D


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Chapter- 5

1)Cost reduction program - theoretical part

2)Cost Reduction Programme of Tata Motors.


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Cost Reduction process

The achievement of real and permanent reduction in the unit cost of goods

manufactured or services rendered without impairing their suitability for the use intended.

Reduction in the cost of product must be brought about by the elimination of wasteful and

resources employed in its design, manufacture, sale and distribution. Reduction in quality

of a product or the range of its uses cannot be regarded as fitting cost reduction.

Cost reduction must be an attitude of mind throughout the organization. it must be

organised and controlled by a senior manager, with a team of skilled people able to analyse

and record business activity and find ways improves the methods used. So that costs are

reduced and output increased. Cost reduction process contains the following sequences ofsteps-:

Analyses:

Every activity, whether in the office, factory, or warehouse, can be analysed and in

to number of separate steps. This is done by asking questions and gathering and recording

answers given. From this process of data collection, it is possible to draw a picture of the

activity that enables it to be examined and improvements developed.

Examination:

Each activity is now examined in some detail to established whether it is

a) Vital

b) Secondary

c) Unnecessary

Vital activities are those, which directly lead to achieving the objective previously

established. They become fundamental to subsequent improvement.

Secondary activities do not contributed directly to achieve the objective but necessary

to support and serve that vital activity.

The reminder of the activities concerned is almost always necessary. As they neither

contributes directly nor indirectly in achieving objective and they can not be considered

necessary.

When activities or components have been examined. It is possible to consider whether

they should be:


47/67



a) Eliminated

b) Combined

c) Simplified.

Elimination of activities and components, the most ambitious and most problematic

step. The greatest saving often arises from elimination of unnecessary activities and

components, and this should always be the first line of attack in spite of the problem

included. Combining activities is one way of making savings in areas where the activity be

eliminated. Considerable improvements can be achieved by combining activities.

Developing solution:

Detailed analyses and examination should lead to the development of

a number of possible solutions. No solution should be overlooked or ignored because it

does not seem practical. The evaluation of a solution will depend upon the knowledge of

the analyst. The evaluation process matches each solution against the following

requirements:

Does it achieve the objectives in full?

Is it practical?

Does it fall within the constraints, if any, such as finance, time, physical

resources, human resources etc?

Is it a better way of doing the job?

Does it reduce cost, if so, by hoe much?

Will be acceptable to customer, employees and management?

Will it stand the test of time?

Selecting a solution:

The choice between several solutions will depend on numerous factors including company

policies, personal preferences, aesthetic appeal, and other subjective criteria. This is stage

where the analyst has to make sure that everyone fully understands the advantages anddisadvantages of various solutions so that a rational choice can be made.

Obtaining agreement:

In the evaluation stage, one of the questions asked was; will be acceptable to customers,

employees and management? The answer to this must have been yes; otherwise the

solution would not have passed the evaluation test. This means that final agreement to the

selected solution has to be obtained by the analyst.


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Cost Reduction Programme of

Tata Motors

The major cost reduction ideas implemented in all parts of the TATA Motors. Listed below

are some cost reduction approaches commonly deployed.

Nature of cost

A) Direct material cost-

Product related

Tear- Down

Zero based costing

Value engineering

Process related

Supplier cost reduction programs

e- Procurement

Supplier base rationalization

Volume negotiations

B) Variable conversion cost

Power consumptionFuel consumption

Indirect material consumption

Tools consumptions

C) Fixed cost

Working capital reduction

Converting fixed cost to variable cost

Productivity improvement

Other methods


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D) Other approaches (impacting all / most of the above areas)

Process improvement

Complexity management/ variety reduction

Waste elimination- use of Kaizen principles

Interest cost reduction.

A) Direct material cost reduction

a.Product related approaches: -

i) Tear-Down

The tear down approach is undertaken to facilitate structured analyses of all components

on the vehicle by involving from diverse backgrounds to question existing assumption

(design/ non-design) and further generate ideas

It is basically involves tearing down of a vehicle or aggregate of a competitor, in

order to identify special features/ attributes of each system / aggregate/ component as

compared to TATA Motors vehicles. The basic purpose of this process is to identify areas

of cost reductions in tata motors designs and process. Ideally it should be done at the

design stage, however, as an on going process it can be done on established vehicles also.

Methodology of teardown

Identify/ study competitors on (information from the annual report etc.)

Financial and cost parameters

Sales volume and revenue

Investment

Make or buy

Technology

Conduct static tear-down collect information on

Total number of parts

Total weight

Units

Part details (length, thickness, weight, weld spots, validity etc)

Number of fixing parts.


50/67



Conduct dynamic teardown collect data on

Manufacturing method

Number of process

Man hours

Assembling

Process parameters

Benefits for using the teardown method

Cost reduction

Information and awareness on latest trends

Supports make Vs Buy decision making

Reduction in development lead-time, process time etc.

B) Zero based costing

The following steps are used for conducting zero based costing

Priorities components groups / sub aggregates for ZBC.

Dismantle the selected aggregates/ sub assembly.

Weight the components.

Arrive at the input weight based on the finished weight and analysis of the

manufacturing process for that component.

Calculate the material cost by multiplying the weight the weighted average cost.

Add to this, the conversion cost for that material group (e.g. machined components,

casting, forging, rubber, plastic etc.)

Add to this the intellectual cost, if any e.g. design and development of component/

tooling by the supplier.

Compare this total cost with the price offered by the supplier.

Identified potential and build case for discussion with suppliers for cost reduction.

Renegotiate for price reduction

Discuss with supplier to jointly work towards achieving potential identified


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C) Value engineering:

Value engineering is a methodology, which can be applied for value improvement

in any area. It is an approach, which analyses all the functions of a product or service and

the related costs involved . based on this analysis, several alternatives are identified, which

can perform the same functions, while reducing the cost the product or service.

Value engineering methodology consists of following steps

1. Orientation phase

Select Projects to be handled by VE team

Appoint The team

2 Information phaseLocate Data from different sources

Identify Facts

Assimilate Facts in the required form

3. Functional analysis phase

List The component of the hardware

Prepare verb- noun description of the function for each

Assembly and component

Established Cost of basic functions

Estimate Worth of each basic function

Determine Value improvement potential

4 Creative phase

Conduct Creative problem solving session

Generate ideas, combine and rearrange them to provide

Ways to accomplish basic function

5 Evaluation phase

Decide Criteria

Evaluate Ideas according to the pre-fix criteria

6 Development phase

Develop New components/ assemblies for acceptance of ideas.

Arrange Trials/test runs


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7 Recommendation phase

Present To the management for approval

8 Implementation phase

Implement Change in production

9 Follow up & audit phase

Resolve Problems identified during implementation.

Problem reported from the field, if any, to establish the

change into a smooth flow up to the customer.

Audit Savings and compare results with original

Report Actual value improvement to the management.

Following are some projects implemented by value engineering teams.

1) Fan drive arrangement-

This project was successfully implemented by the engine team, which resulted in

optimizing the fan drive arrangement. In this particular case, two separate belt drives were

combined into one. In addition to a saving of Rs 2000, benefits of productivity

improvement, variety reduction and standerdisation were also achieved.

2) Air filter assembly-

Air filter assembly on a vehicle consisted of a hose and hose clip assembled on the inlet of

air filter. The VE team proposed to integrate these in to one assembly. A sheet metal tube

replaced the hose and it was made an integral of the air filter.

b) Process related approaches:

IV.Supplier cost reduction programmes-

Direct material cost reduction achieved by obtaining price reductions from suppliers

without reduction in either fixed or variable cost at suppliers end will result in:

Reduction in bought- out for company

Reduction in profit margin for the suppliers

Increase in break-even volumes for the suppliers


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The key characteristics of the supplier cost reduction programmes are as follows:

Target driven

Clearly defined targets

Targets for suppliers as well as internal targets

Targets in terms of number of proposal or ideas, savings achieved etc,

Partnership approach

High involvement of supplier in generation of ideas for cost reduction

High involvement from company side in providing assistance to suppliers to

achieve cost reduction.Benefits to both supplier and TATA Motors

Win-Win situation

Sharing of gains achieved through cost reduction

Reward to suppliers

Supplier margins protected and or improved

II. e- procurement-

e- procurement is internet based interactive platform for procuring any type of

goods or services through the medium of reverse auction. The e- procurement tool brings

tremendous benefits to the procurement process in terms of reduced cycle time, greater

efficiency and transparency.

e- procurement allows a buyer to invite any supplier across the world to a reverse

bidding auction, the sole requirement being access to the internet. Reverse binding auction

are open for a defined and limited period of time, with market price feedback available to

participating suppliers. Bidding times can be extended automatically to allow for frenetic

bidding activity towards the close of the auction. the system allows the highest degree of

fairness to all the participants.

e- procurement process has the following steps

Identifying aggregate component or raw material for the auction.


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Pre-auction preparations new supplier identification (if required), sending

drawings to invited vendors concerned and resolving queries.

Plan for auction fix date and time.

Finalising and floating request for questions.

Manual round for quotations.

Conduct event.

Finalise post bid allocation and raise purchase orders.

Approval and development of new suppliers, if required.

Tata motors tied up with a consulting firm, for conducting

e- procurement through two streams i.e. full source and quick source.

Under full source, Tata Motors have access to the full range of consulting servicesincluding event management and market making.

Under quick source projects are managed end to end by our and involve relatively

lower degree of purchase complexity.

Using this process Tata Motors has procured several products such as tyres, bearings,

castings or forgings, leaf springs, eat belts and services such as transportation.

III. Supplier base rationalization-

Supplier base rationalization consist of the following steps:

1. Categorisation of material group-

Categorisation of each part in the material category in to sub- categories based on

type and manufacturing process.

2. Removal of tail of supplier base:

Elimination of non performing or low business value suppliers, supplying few

numbers of parts.

3. Masop elimination-

Elimination of Masop and identification of potential bought out suppliers.

4. Tearing of suppliers/ of loading assemblies:

Identification of sub- assemblies and aggregates to be outsourced from a tier 1

supplier.

5. Supplier base consolidation-

Elimination of small direct suppliers arising from outsourcing of sub- assemblies.


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6. Removal of multi sourcing-

Reduction in part- supplier combinations by moving to dual sourcing.

Process of Tail removal

Identify and priorities suppliers in Tail for deletion

Identify c class supplier supplying. e.g. last 1 for 2% of purchase value.

Priorities the suppliers for elimination based on value of business and number of

parts supplied to ensure ease of capability/ capacity transfer.

Suppliers with low value of business and low number of parts to be considered first

for elimination.

Identify potential alternative sources to which the business of the suppliers to be

deleted can be transferred.

IV. Volume negotiations:

Though the approach appears to be useful only to the materials department, all of

Tata Motors should be alert to the possibilities of negotiating a better price with existing or

alternative suppliers as soon the opportunity presents itself.

Some essential of a Good negotiation are:

Check out price and quality of the material at some other sources company must

have good knowledge of what is available from where.

Based on the suppliers capacity, capability and past performance, offer him more

share of business for a reduction in price.

The analysis of zero based costing and product, aggregate benchmarking should be

used to negotiate a reduced price.


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B) Variable conversion cost reduction-

I. Power Consumption-

In Tata Motors, there are many methods by which power consumption can be controlledin plants and offices. One may take help of a third party, to find out areas of energy losses.

Examples of power consumption-

Electricity at unity power factor drawn from electricity boards.

Optimization of capacities of various equipment through innovation.

Use of furnascote special paint for heat treatment furnace.

Use of timer control for machines and utilities to reduce idling losses.

Purchase of wind power electricity from third party.

Optimization of chilling plants and air conditioning plants in paint shops.

Modification of pneumatic lines to reduce load on centralised air compressors.

II.Fuel consumption-

Examples of fuel consumption

Use of light diesel oil (LDO) instead of certifigured LDO in paint shops.

Modification of surface oven air heater to reduce hot air leakage or losses.

Fine tuning of oven burners to increase efficiency of combustion.

Installation of high temperature resistant sensors for operation of oven doors in

automatic mode.

III.Indirect material consumption-

Examples of Indirect material consumption

Use of belt type oil skimmer units to enhance life of coolant.

Exploring of reverse auctioning opportunities for the purchase of consumables

IV. Tools consumption-

Examples of reduction in direct material consumption in Tata Motors plants are

given as below:

Use of carbide indexable tips in place of brazed carbide tools for stub axle gap

milling to eliminate breakage.


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Use of solid carbide drills in place of brazed carbide drills for front Axle beam to

enhance tool life.

C) Fixed cost Reduction-

I. Working capital reduction-

The investment in working capital is influenced by four key events in the

production and sales cycle:

Purchase of raw of material.

Payment of raw material.

Sales of finished goods.

Collection of cash for sales.

Tata Motors begin with the purchase of raw material or bought out, which is paid for after

a certain time frame. This material is converted into finished goods and then sold to the

customer. Customer pay their bills some time after the sales. The cycle completes with

payment made by the customer for the goods.

The faster the cycle is completed, faster are profits generated. Thus, main purpose

of working capital reduction is to have shorter inventory and receivable periods.

Example of How to reduce inventory in Tata Motors -

Standardising the stocking norms at factories for all items.

Undertaking kaizen events, which includes one piece of floe, layout changes, two

bin system.

Salving non-moving or slow moving inventory.

Established a central receipt and documentation office (CRDO)

Just in time delivers to line.

II. Converting fixed cost to variable cost:

In the Tata Motors, company utilized the surplus capacity (fixed cost) available in

company shops, without detracting from the main responsibility of producing vehicles and

in the process, converted some of the fixed costs into variable nature. In fact, these

products from an important part of the non-vehicle business,


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Some examples are given below-

In addition to vehicle engines, Tata Motors engine shops also manufacture engines

for industrial applications.

Divisions like production engineering, forge and foundry manufacture products for

external customers, to utilize their capacities.

IV. Productivity improvement:

In TATA Motors the manpower cost is generally at number two , only after material cost.

Tata motors looking at productivity of both direct as well as indirect men..

Direct men-

Direct men are those who are responsible for changing the shape of the part or

assembly. thus, members of the company who are working on machines, assemblies may

be group in direct men category.

Example if in every production cycle the machine operator is required to wait for the

previous operation to complete, the company will be forced idleness because of which

company costs will go up. In such case company find ways to eliminate idleness.

Similarly if the supervisor asks operators to produce parts irrespective whether required by

the next machine or not, will result in increased inventories and thus additional costs.TATA Motors nave been deploying Kaizen methodology to improve productivity on the

shop floor and have achieved results.

The kaizen methodology employs a cross functional approach to observe

wastage or Non-value adding activities in the men machine environment. at the end of

two week productivity improvements, reduction in the defects, and inventories reduction of

the order of 30 to 40% are achieved.

IV. Other method-

a) Welfare:

Restructuring of reimbursement scheme for medical expenses on hospitalisation.

Reduction in canteen expenses.

b) Rent, rate and Taxes:

Re- validation of regional offices and stockyards.


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The

the financial statement analysis and cost reduction program at tata motors ltd. by chetan aher

Documents

financial statement

tata motors profile1

cost reduction progamme4

cost reduction process4

subsidiaries of tata

chetan aher

telco tata engineering

trend analysis meaning3