rohit india
DESCRIPTION
Rohit IndiaTRANSCRIPT
Transfer of RMs from “Lakshmi Godown (Cuddalore - TN)” to “Rohit (I) foods division (Pondy)”, Form for stock transfer as required under Central Sales Tax act is not being issued for such transfer. (Para 1 (e))
Observed stock out of certain materials during the period from 26th June to 4th October the (Para 4(b)) Refer annexure 2
Production plan for3rd & 4th week of JC for “50 paise tomato garlic” was not executed as there was stock out of “50 paise tomato garlic” laminates from 11th July 2008 to 16th July 08 . For bin card details refer the Exhibit .(para 4(c))
Loss or Destruction of Asset:
No restricted access controls inside the work floor. (Para 2(c))
“Specimen authorisation list” for both NRGP & RGP from the “chief department heads” of the unit were not available in the material gate. (Para 2(d))
No controls over the returnable containers (carbuoys for storing pickles & brines) (Para 2(e))
Returnable items wrongly captured in non returnable register & Non returnable items wrongly captured in returnable & observed instances of returnable items pending for more than 3 months. (Para 2(f))
“Insurance cover & details” were not available for any of the fixed assets in the unit
Stacking norms not being followed in the godown & stores in stacking of raw materials such as bottles & carbuoys. (Para 5 I(a))
As per the stacking norms of the SOP, every carton shall be palletized but it was not found to be in practice in the unit. (Para 5 I(b))
No dedicated place (bins/ bays) for storing expired, damaged and rejected materials in the FG godown (Para 5 I(d))
There is no BIN system in place for any material movements & all the carbuoys containing pickles & brines were mixed with other carbuoys containing rice brand oil, salt etc. (Para 5 I(d & e))
Majority of the carbuoys containing brines and pickles were not coded with the GRN number .The carbuoys were not stacked variant wise and
were scattered all around the Godown. Besides, found dented carbuoys stacked underneath good carbuoys. (Lakshmi Godown) (Para 5 II(a))
No fire extinguisher was found anywhere in the godown & pest controls were not in place. (Para 5 I(b))
Conflict of Interest:
All the fixed asset invoices (except for factory shed & other infrastructure expenses) are in the name of “Rohit India” instead of CKPL whereas; the insurance coverage of the same is taken care by “CKPL”. (Para 3(c))
No clear “memorandum of understanding” between the two entities on the ownership & usage of fixed assets. (Para 3(c))
Erroneous Record and/or incomplete Information:
Production department is not signing the conversion details in the “daily conversion note” (to vet the data) before raising conversion orders in S-A-P (Para 1 a).
The “stores in charge” (who is being physically placed in Rohit (I) foods division, Pondy) vouches for the receipt of raw materials in GRNs pertaining to “Lakshmi Godown, Cuddalore”.(Para 1b)
GRN is being raised for the net quantity of goods (gross quantity received less rejections) rather than for the gross quantity of goods received. (Para 1(c))
Stock transfers from one TPU to another TPU were not accompanied by stock transfer note in several cases. (Para 3(c))
No provision for differentiating packing materials (unused inputs - which are in stores) with that of its WIP issued for production. (Para 4(d))
No practice of returning the PMs to “stores” by “production” and whatever that is being posted in SAP as return is only a PAPER RETURN. As a result, there will always be a mismatch in book stock between S-A-P & in the books of “Rohit (I) pickles division”. (Para 4(d))
Variances were observed while correlating the “book stock maintained by Rohit (I)” with the “S-A-P closing stock” of CKPL. (Para 5I(c))
Variances were observed during physical verification of raw materials (brines & pickles) stored in the “Lakshmi godown” (Sampling: 18%).(Para 5II(d))
Unrealized or Lost Revenue:
Expired laminates were RECODED with revised month & year through hired machinery inside the premises from DP Bharat Products” & “Shree Enterprises Erode”. The hire charges paid by Rohit (I) foods from April 08 to October 08 (subsequently reimbursed by CKPL) amounts to 2.25 Lakhs. (Para 4(a))
Unacceptable Accounting Principles:
High Costs and Probable Loss of Asset:
It is recommended to ascertain the RM stock holding levels (maximum, minimum, reorder, safety & danger level) for the conversion unit to avoid piling-up of stocks. (Para 1(d))
Both returnable (RGPs) & non-returnable gate passes (NRGPs) were raised in the same GP format & Gate passes have manually numbered rather than pre-printed numbering system &No separate fields for “return date” & “tentative date of return” available in the returnable gate pass register. (Para 2(b))
There is no dedicated place for storing expired, damaged and rejected materials & there is no BIN system in place for material movements. (Para 5II(c))
Inappropriate Management Policy and/or Decision Making / Business Divergence:
Failure of Support Services:
CCTVs were not installed anywhere in the premises. (Para 2(a))
Visitors log sheet rather than visitor’s register is being maintained & n o practice of issuing visitor passes to the visitors / outsiders (Para 2(a)).
OBSERVATIONS
1. TCU OPERATIONS
(a) While verifying the “daily conversion note” maintained in the unit, it was
observed that the production department does not sign the conversion details (to vet the data) before raising conversion orders in S-A-P.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionAuthenticity of the conversion note raised to production department cannot be verified.
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that the conversion order written in the note is signed by a authorised person from production department
-
Responsibility
Operations – CKPL
Unit ResponseAction PlanAction Plan Date
(b) While verifying the process of raising GRNs for goods receipt, it was observed that the “stores in charge” (who is being physically placed in Rohit (I) foods division, Pondy) vouches for the receipt of raw materials in GRNs pertaining to “Lakshmi Godown, Cuddalore”.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionAuthenticity of the GRN raised cannot be ensured as it is being vouched by a person who is not present in the Godown
High Moderate Moderate High
Control Lapse as the GRN for both Rohit India & Lakshmi Godown is authorised by same person.
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that GRN for Lakshmi Godown is authorised by a person other than the one who is the stores in charge of the Rohit India
-
Responsibility
Operations – CKPL
Unit ResponseAction PlanAction Plan Date
(c) During the course of audit it was observed that GRN is being raised for the net quantity of goods, gross quantity received less rejections, rather than for the gross quantity of goods received. It results in open items in GR account, which cannot be cleared because the PO quantity and the GRN quantity won’t match and shows goods pending to be receivedFor further details refer A nnexure1
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionGR account shows a wrong picture as “goods pending to be received” from vendor
High Moderate Moderate High
Vendor parameter analysis cannot be done as the quantity of goods rejected cannot be ascertained.
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that the GRN is being raised for the gross quantity rather than for net quantity.
Responsibility
Operations – CKPL
Unit ResponseAction PlanAction Plan Date
(d) During our audit visit, it was observed that the daily production execution of the TCU is 20 tons (altogether for all the variants) whereas the existing minimum & maximum RM stock level ranges from 300 to 350 tons (Lead time: 15 – 18 days).
By enquiry, we found that the stocks that are being sent from Abhiruchi, Mallipudi will be converted in to finished product within 7 to 8 days. Therefore, the ideal production lead-time (after considering all uncertainties) works out to maximum of 10 days & the ideal stock holding level would be 200 tons.It is recommended to ascertain the RM stock holding levels (maximum, minimum, reorder, safety & danger level) for the conversion unit so that this will have the following advantages:
Piling-up of stocks can be avoided. Thereby, godown space can be managed efficiently. Expiry & damage of RM stocks can be prevented. Thus, working capital blockage can be curbed.
Existing Stock Level (Tons) 300 to 350 tonsExisting Lead time (Days) 15 to 18 days
Ideal Stock Level (Tons) 160 to 200 tonsIdeal Lead time (Days) 8 to 10 days
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChances of expiry of stocks exist.
Low Moderate Moderate High
Chances of space constraint in godown and stores exist
Low Moderate Moderate High
Chances of blockage of funds in form of piled up stock exist.
Low Moderate Moderate High
Action Required-:
Preventive Detective Corrective
Type of Action
RM stock holding levels (maximum, minimum, reorder, safety & danger level) for the conversion unit should be ascertained.
Responsibility
Purchases & Operations – CKPL
Unit ResponseAction PlanAction Plan Date
(e) There are two inter state stock movements observed:
First, the RM stock is being despatched from “Abhiruchi (Mallipudi, AP)” to “Lakshmi Godown (Cuddalore, TN)”. For this, the stock transfer declaration forms (as required by CST Act) are being duly issued for all the consignments.
Whereas, for transfer of RMs from “Lakshmi Godown (Cuddalore - TN)” to “Rohit (I) foods division (Pondy)”, no such form is being issued. This is a contravention of the relevant section in the CST Act.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionContravention of CST act will attract penalty
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that FORM as required by CST act is issued for stock transfer.
Responsibility
Logistics & Operations – CKPL
Unit ResponseAction PlanAction Plan Date
2. SECURITY CONTROLS
(a) During our audit visit, a survey of the existing security controls in the unit was made & observed the following:
CCTVs were not installed anywhere in the premises.
Visitors log sheet has been maintained & updated by the security staff in the unit rather than visitor’s register. Moreover, there is no practice of issuing visitor passes to the visitors / outsiders.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChances of pilferage/ burglary going untraced due to Non installation of CCTV
Low Moderate Moderate NA
In case of visitors log sheet information like address, phone number, purpose of visit is not captured so risk of not knowing about the visitors exist.
High Moderate Moderate NA
In case of non issue of visitor’s gate pass chances of visitors not being distinguished from employee exist. Like wise the authenticity of the purpose of visit also cannot be ensured.
High Moderate Moderate NA
Action Required-:
Type of Action
Preventive Detective CorrectiveInstalling CCTVs can create moral responsibility among the loading supervisors and associates as they are being watched, and it will provide better control and prevents any pilferage.
Ensure Gate pass is issued to the visitors
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(b) We observed that the gate pass slip contains an option to mark the gate pass as returnable (RGPs) or non-returnable gate passes (NRGPs), so there exist a possibility of marking gate pass wrongly. It is suggested to have a separate gate pass for returnable / non returnable items. Furthermore gate pass have manual numbering system rather than pre-printed numbering system.
The exhibit of the same is available in exhibit .”Gate pass.JPG”
Moreover, no separate fields for “return date” & “tentative date of return” were made available in the returnable gate pass register.
Risk Analysis:
Risk Factor Risk Assessment
Frequency of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChances of returnable item wrongly marked as non returnable cannot be avoided.
High Moderate Moderate High
Loss of capital asset High Moderate Moderate High
Missing out the numbering sequence can result in losing track of items that was sent out.
High Moderate Moderate High
Non mentioning of tentative date of return can result in loosing track of items that were sent out.
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveThe above lapses shall be rectified & streamlined hereafter by the concerned departments
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(c)We also observed that there was no restricted access controls inside the work floor. There were no one to watch over the movement of strangers & outsiders inside the work floor.
Risk Analysis:
Risk Factor Risk Assessment
Frequency of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionPilferage of goods/tools cannot be avoided.
High Moderate Moderate High
Security threat High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that a security is posted at the entrance of the work floor to monitor the movements
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(d) During the course of audit, it was observed that the “specimen authorisation list” for both NRGP & RGP from the “chief department heads” of the unit were not available in the material gate. This system will make aware the security guards (on duty) about the authorised signatories who can pass RGPs & NRGPs in the unit, which will strengthen the material outward movement controls of the unit.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChance of unauthorized outward material movement cannot be avoided.
High Moderate Moderate High
Loss of capital asset High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that “specimen authorisation” list is made available to the security at the gate.
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(e) It was observed that the unit does not have controls over the returnable containers (carbuoys for storing pickles & brines) in the unit. The unit utilizes carbuoys ranging from 50kg to 60kg capacity both in Pondy & Cuddalore (Lakshmi godown), but no controls were put into practice for the same.
Risk Analysis:
Risk Factor Risk Assessment
Frequency of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChance of carbuoys being stolen cannot be avoided.
Moderate
Moderate Moderate High
Revenue loss as each carbuoys cost more than Rs 400
Moderate
Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure a tracking mechanism is put in place to track the inward & outward movement of carbuoys
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(f) During our audit visit, we verified the gate passes & the registers maintained at the factory gate & observed the following:
Some of the “non-returnable items” have been wrongly captured in “returnable register” by the security guard(s). The following are the instances:
S No Date Particulars of Description Reason / Purpose
1 14-05-08Oil gel 45x65x10(Damaged) &
bearing (damaged)Sample to Ravindran,
CKPL Chennai
2 23-05-08 Lime sachet strip 10 GM x 9 NOS CKPL – Chennai
3 27-08-08 SS table Rohit India, Cuddalore
4 01-09-08 3 HP motor Make CGTransfer to Chikki
division
Same as above, some of the “returnable items” were wrongly captured in “non -returnable register” which are tabulated below:
S.No
Date Description Purpose
1 17-04-08 Godrej Lock & KeyFor EB
Kaatukupam give to Malayan
2 17-04-08Laminate mango & tomato garlic 50ps total 11 packs
PIPL Pondy
The following are some of the materials that are pending to be returned for more than 3 months.
SI No
Date Description Purpose
1 12-04-08Motor ½ HP 220v 1 No ,GC power
system, CuddaloreNot mentioned
2 20-06-08Ruchi Empty 300 GMs bottles 1
boxTo CFC sample
purpose
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionLoss of capital asset as returnable is captured in non returnable.
Moderate
Moderate Moderate High
Misleading information as non returnable is captured in returnable register.
Moderate
Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure the asset movement is rightly captured in the right register.
Reconciliation of information captured in the registers should be done on periodic basis.
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
3. CONTROL ON FIXED ASSETS
(a) The following are the latest stock insurance details available in the unit & copy of the policy renewal was not available with the unit.
S.No
Insurance Company
Type of Insurance Cover
Covered for
Period Sum Insured
(Rs)
Status
1 IFFCO – TOKYO
Burglary Food products at dehydration factory
07.02.07 to 06.02.08
12500000
Expired
2 IFFCO – TOKYO
Standard Fire & Special Perils
Food products at dehydration factory
07.02.07 to 06.07.08
Break up NA
Expired
Action Required-:
Preventive Detective Corrective
Type of ActionMake available to the unit a copy of the latest insurance policy -
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(b)Besides above, it was observed that “insurance cover & details” were not available for any of the fixed assets in the unit (by enquiry, it was informed to us that CKPL - HO had conducted “physical verification of fixed assets” in the unit on 02.09.08 for the purpose of insurance cover but insurance copy was not available in the unit at the time of audit).
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionFinancial loss due destruction or impairment of asset cannot be mitigated
Low Moderate Moderate High
Action Required-:
Preventive Detective Corrective
Type of Action
To ensure that the Insurance cover is taken at the earliest for TPU held assets.
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(c) Furthermore, all the fixed asset invoices (except for factory shed & other infrastructure expenses) are in the name of “Rohit India” instead of CKPL whereas, the insurance coverage of the same is taken care by “CKPL”. It was observed that there were no clear “memorandum of understanding” between the two entities on the ownership & usage of fixed assets.
Documentation on asset transfer: Stock transfers from one TPU to another TPU were not been accompanied by stock transfer note in several cases.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChance of legal complication in insurance claim in case of any untoward happening.
Moderate
Moderate Moderate High
Action Required-:
Preventive Detective Corrective
Type of ActionAgreement to the above effect can
be entered into at the earliest.
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
4. CONTROL ON RAW MATERIALS / PACKING MATERIALS
(a) During the course of audit, it was observed that the “material planning” of laminates (PM) was not been properly done.
Due to this, the expired laminates were RECODED with revised month & year through hired machinery inside the premises from DP Bharat Products” & “Shree Enterprises – Erode”. The hire charges paid by Rohit (I) foods from April 08 to October 08 (subsequently reimbursed by CKPL) amounts to 2.25 Lakhs. Refer Exhibit2, Exhibit3
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionFuture financial loss due to expiry of laminates cannot be prevented if proper material planning is not done.
Moderate
Moderate Moderate High
Action Required-:
Preventive Detective Corrective
Type of ActionRecoding cost can be avoided if proper material planning is done.
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(b)During the audit it was observed that certain materials had stock-out status during the period from 26th June to 4th October the details of which are provided in the annexure2.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionFinancial loss as the production plan was not executed to meet the demand for the product.
Low Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective Corrective
-Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(c)Furthermore, it was observed that the production plan for3rd & 4th week of JC for “50 paise tomato garlic” was not executed as there was stock
out of “50 paise tomato garlic” laminates from 11th July 2008 to 16th July 08 . For bin card details refer the Exhibit
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionFinancial loss as the production plan was not executed to meet the demand for the product.
Low Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective Corrective
-Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(d) During the course of audit, it was observed that there is no provision for differentiating packing materials (unused inputs - which are in stores) with that of its WIP issued for production.
We enquired on this and observed further that at the end of each day, the information pertaining to issues and return of unused packing materials is passed on by “stores” to “accounts” for posting the same in S-A-P. We found that there was no practice of returning the PMs to “stores” by “production” and whatever that is being posted in SAP as return is only a PAPER RETURN. As a result, there will always be a mismatch in book stock between S-A-P & in the books of “Rohit (I) pickles division”.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
Detection
Generation of incorrect MIS cannot be avoided.
High Moderate Moderate High
Accurate quantity of physical stock in stores cannot be known.
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveExplore the possibility of generating a report in SAP that captures work in Progress.
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
5. GODOWN OPERATIONS
I. Rohit (I) FG Stores, Pondy
(a) No stacking norms being followed for the raw materials like bottles & carbuoys in both the godowns (Exhibits 4)
(b) As per the stacking norms of the SOP, even cartons shall be palletized but it was not in practice at the unit (Exhibit 5)
(c) No variances were observed while verifying physical stock with the book stock as maintained by Rohit India. However, discrepancies were observed while correlating the “book stock maintained by Rohit (I)” with the “S-A-P closing stock” of CKPL. The details of the same are available in Annexure -3
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
Detection
Possibility of damaging of stock exits.
Moderate
Moderate Moderate High
Stock out cannot be avoided as the SAP stock is not matching with that of the actual stock.
Moderate
Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveThe reason as to why there is a difference between SAP stock level and the actual stock level exist should be looked into and rectified.
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(d) We further observed that there is no dedicated place (bins/ bays) for storing expired, damaged and rejected materials in the FG godown. There is no BIN system in place for any material movements.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChance of damaged goods dispatched/issued for production cannot be avoided.
High Moderate Moderate High
Mixing up of variants cannot be avoided as there is no BIN system in place
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that a dedicated place is made available for storing damaged goods.BIN system can be introduced for effective inventory management
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(e) While visiting RM stores, we observed that all the carbuoys containing pickles & brines were mixed with other carbuoys containing rice bran oil, salt etc.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionIdentification & issue of variants becomes difficult.
Moderate
Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that the raw materials are stacked variant wise. -
Responsibility
Operations
Unit ResponseAction Plan
Action Plan Date
II. Lakshmi Godown, Cuddalore
During our audit exercise, we visited the godown situated in Cuddalore (Lakshmi Godown) and observed the following:
(a) Majority of the carbuoys containing brines and pickles were not coded with the GRN number (See Exhibit3 )
The carbuoys were not stacked variant wise and were scattered all around the Godown. Besides, we found some dented carbuoys being stacked underneath along with good carbuoys.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionIssue of Raw material on FIFO method becomes difficult as the carbuoys are not coded with GRN
Moderate
Moderate Moderate High
Identification & issue of variants becomes difficult as they are not stacked variant wise.
Moderate
Moderate Moderate High
Threat of carboys falling down & getting damaged exist as the good carbuoys were stacked upon dented ones
Moderate
Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveMake sure that each carbuoy batch is coded with its respective GRN.
Ensure stacking norms is followed
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(b) Not even a single fire extinguisher was found anywhere in the godown & pest controls were not in place.
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionDestruction of RM due to fire cannot be prevented.
High Moderate Moderate High
Contamination of RM cannot be prevented as there is no pest control measure.
High Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective CorrectiveArrange for a Fire extinguisher.
Put in place a pest control measure.
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(c) There is no dedicated place for storing expired, damaged and rejected materials & there is no BIN system in place for material movements.
Risk Analysis:
Risk Factor Risk Assessment
Frequency of
Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
DetectionChance of damaged goods dispatched/issued for production cannot be avoided.
HighModerat
eModerate High
Mixing up of variants cannot be avoided as there is no BIN system in place
HighModerat
eModerate High
Action Required-:
Type of Action
Preventive Detective CorrectiveEnsure that a dedicated place is made available for storing damaged goods.BIN system can be introduced for effective inventory management
-
Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
(d) We conducted physical verification of raw materials (brines & pickles) stored in the “Lakshmi godown” & variances were observed which are as follows: (Sampling: 18%). For details refer Annexure 4
Risk Analysis:
Risk Factor
Risk AssessmentFrequen
cy of Lapse
Probability of Risk
Severity of Impact
Likelihood of Prior
Detection
Inadequate controls in stock receipting & issues
Low Moderate Moderate High
Actual stock available at godown cannot be ascertained immediately unless physically verified.
Low Moderate Moderate High
Procurement of incorrect quantity of RM is possible if the availability of stock not known correctly.
Low Moderate Moderate High
Action Required-:
Type of Action
Preventive Detective Corrective
-Responsibility
Operations
Unit ResponseAction PlanAction Plan Date
6. ASSURANCES
(a) We verified the documents & register pertaining to calibration & AMC of fixed assets (including spare parts) & observed to be satisfactory.
(b) During our visit, we verified the “customer complaints register” maintained at the unit. It was observed that all the registered complaints were duly attended by the operations team & no complaints were left unattended.
(c) We also verified the documents / registers maintained by the
quality assurance department & it was observed to be satisfactory & kept current.
(d) The documents & appraisal process pertaining to scrap sales were also been verified & observed that none of the scrap / waste were being sold at uncompetitive rates.