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Material Flow Reconciliation in A Cement Activity - June 2012
Material Flow Reconciliation in A Cement Activity - June 2012
- June 2012 -
1
Before start
Volume reconciliation is often identified as an area to improve in many
Countries based on internal assessment & external audit.
The Group Internal Control and Group Finance Control department
have designed this document on controls over material flows in the
cement activity to help improve Lafarge ability to manage volume
reconciliation and will cover:
material flow in a cement activity and associated risks and controls
how to set up a monitoring process
frequently encountered issues
2
Index
3
Index
4
Analyze the Material Flow
Manufacturing
!
Dispatch
!
Cement,
Additives
!
Clinker, fuel
!
Raw mill
5
Analyze the Material Flow
Manufacturing
Weigh feeder under the conveyer Risk linked with volume reconciliation:
Low stock value, difficult to move
Low the materials
6
Analyze the Material Flow
Manufacturing Prehomogenization* & Raw mill
Major stock item: Crushed limestone, pyrite,
silica, clay, Iron ore
Stock owner: Production manager
Measurement
Stock take of piles: volume measured by total
station * density determined by Lab
Receiving of purchased material: Weighbridge
Consumption:
Pressure with pneumatic conveying
system ton/hour
Bucket elevator ton/hour
Weigh feeders
Challenges for control:
Weighbridge
Reliabilityof measurement equipments:
maintenance and calibration
Consistency of production ratios over a period or
between the ratios
Pile storage condition
Quality and quantity control at receiving
Weigh
Bucket elevator feeder
Risk linked with volume reconciliation:
High value of some additive materials,
* Not in all the plants
Medium theft, fraud on quality control, collusion with
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supplier
Analyze the Material Flow
Manufacturing
Clinker production
Major stock item: Raw meal, clinker, fuel (coal)
Stock owner: Production manager
Measurement
Receiving of purchased material: Weighbridge
Consumption:
Bucket elevator and weigh feeders ton/hour
Clinker production can not be easily measured. It is
calculated with production ton/hour
• Clinker (t/h) = Raw meal (t/h) * 0.55~0.65 (lab)
Challenges for control
Consistency of production ratios over a period or
Good Practice
between the ratios
Objective : test the reliability of Reliability of laboratory ratios (moisture, density …)
clinker production hour rate
Monitoring of material movement (night reception,
Practice : Clinker production count
12/24 hours by truck + weighbridge transfer)
Suggested frequency : once per
year
Risk linked with volume reconciliation:
High stock value (e.g. coal)
theft, fraud on quality control, collusion with
High supplier 8
Analyze the Material Flow
Manufacturing
Cement production
Major stock item
Clinker,
gypsum, slag, cement in silo, cement in bag,
packaging material (pallets, bags)
Stock owner
Production/Dispatching manager
Measure method
Weighbridge for receiving (e.g. slag)
Weigh feeders under conveyor
Calculate cement production ton/hour
• Cement production (t/h) = Clinker (t/h) + Additives (t/h)
Stock pile : volume measurement * density
Cement silo : drop rope
Bag, pallets : count
Challenges for control
Relevance of production rate
Reliability of measurement equipments: maintenance
and calibration
9
Analyze the Material Flow
Transfer, Reception at depot and Dispatch
silos
dispatch
bags
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Material flow controls 1/6
Controls embedded in operations
Receiving
(raw materials: lime stone, marl, silica, iron ore, gypsum, slag, coal …)
• Weighbridge reliability
• Weigh feeder reliability
• Quality : moisture rate, systematic or by
sampling
Production
(mid-products, cement bulk/bag)
Obtain data
Each operational department (stock owner) is responsible of these controls at ongoing basis.
Finance department participates at the closing period for a more in depth control.
Production = Sales - Purchase – Inventory volume (kt), % : Sheet “DataEntry”, row 982
Cement volume* Movement Impact on variance analysis (€): sheet “Variance”, row 266
Production = Sales - Purchase - Inventory volume (kt), % : Sheet “DataEntry”, row 986
Clinker volume* Movement + Cement Production/ CK ratio Impact on variance analysis (€): sheet “Variance”, row 267
Inventory Movement variable cost in P&L =
Inventory Produced clinker stock increase * variable
movement cost of clinker /t + Produced cement stock Impact on variance analysis (€): sheet “Variance”, row 263
variable part (€) in
increase * average manufacturing variable
P&L**
Cost for domestic sales except clinker
Average Specific Heat Cost (€/GJ) = Fuel
Cost in P&L (€) / Clinker production (t) / Specific Heat Cost (€/GJ): Sheet “DataEntry”, row 990
Fuel
Specific Heat Consumption by ton of clinker Impact on variance analysis (€): sheet “Variance”, row 182
(GJ/t)
* Inventory of Purchased Cement, Clinker, Raw materials does not participate to the variance analysis (P&L) in CDP. Therefore,
reconciliation performed by CDP is ONLY based on Produced volumes. Please interpret “Cement sales volume” as “Sales volume of
produced cement” etc. 15
** There can be an inconsistency if the increase of stock is linked with a new product.
Material flow controls 5/6
Some reconciliations in Cement Package
Cement Package (CDP) provides automatic check on the coherence of
some KPIs
Refer to the color alerts (black, red, orange) according to significance of
inconsistencies
In “DataEntry” sheet
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Material flow controls 6/6 Internal Control Standards
ICS code Control Risk
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Index
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Establish the process of material flow control:
Step 1 : Have a full picture of flows and identify risky areas
Evaluate the reliability of information flow and identify risky areas and
key materials
Rational evaluation from experience
Test *
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Roles of business process owners on Internal
Control
BPOs (Business Process Owner) or Stock owners design the
controls to be implemented, perform reconciliation as per defined
frequency and method, investigate and implement corrective
action
• Manufacturing : Quarry, Production, Process managers
• Dispatching & Transfer : Logistic, Dispatching managers
• Annual stock take : Finance manager
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Index
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Frequently encountered issues and Good practices
1/3 Frequency, Density, Moisture, Off-spec, Tolerance rate
Frequency of stock take
Comply with Group guidelines and instructions
Consider local ability and added-value
Density and moisture
Dry quantity must be displayed in the system
Reconciliation based on dry quantity (recommendation)
Difficult to systematically measure all materials before the stock take
• Practice : Test when big variance occurs
Off-spec semi-finished or finished products (Clinker e.g.)
Risk of distortion of unit cost of production, lack of visibility to the quantity
of product with poor quality and late reactions
Off-spec product should not be recorded as production.
Tolerance rate
Depends on the specificity of the pile : Volume, storage condition,
turnover, type of material
Practice : observe the evolution of stock take variances and set up the
tolerances
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Frequently encountered issues and Good
practices 2/3 Adjustment after the stock take
Situation Accounting Solution
• Variance occurred during the current year
• Mid-product & processed materials (raw Adjust Consumption
meal, fuel mix ...) or Production
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Index
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Group Referential documents and projects
Procedures:
Treatment for Off-Spec clinker in Accounting and Performance
measurement (Cement Control, 2010)
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Index
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Annex
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The End
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Annex : Main Group audit findings and risks –
Material Flow Reconciliation ( 9 BUs in 2010)
• Frequency, Method
• Lack of reconciliation check, or no corrective action
Improper stock take • Lack of control on stock adjustment
• Inefficient Interface
IS/IT systems not • Reconciliation & control report not used
supporting effective • Manual operations bypassing system
control of operation
• Modifiable weighbridge, batching
• Separation of materials
Physical storage • Access security
Risks
•unreliable data from operation system
•reporting not aligned with reality
•fraud due to lack of control
•asset security, damage and concrete quality
•poor utilization of resources
Source: LGA data compiled for reporting and feedback. Analysis and ratio (%) based on 9 BUs audited in 2010 31
Annex: Group Audit Approach on Material flow
Actors: Finance/Stock owners Actors: Finance/Purchasing
Doc: Count sheet, calculation sheet Doc: Call for tender documents
Survey reports, reconciliation reports Validation per DOA
Audit approach
Recurring Questions Return
Basic data reliable?
Measure equipment / method Actors: Sales admin./Dispatch/Logistics
Actors : Purchasing/Warehouse/Logistic Report data consistent? Doc: GDN
Doc : GRN Information flow
Under control?
Reconciliation done independently
Receiving Gap investigated and resulted in
action plan
Approach:
Test reconciliation Dispatch
Stress on manual operations
Actors: Sales admin./Dispatch/Logistics
Doc: GDN
Issuing Production
(spare parts or other suppliers) (Consumption & production)
Sample information 33
Annex: Challenge Production report with
mesured data
Sample information 34
Annex: Analyze on monthly evolution of stock
take discrepancy (set up of tolerance rate)
Sample information 35
Annex: Required frequency for some operational
controls on inventory
Production data reconciliation
Monthly Cement bulk materials: stock take by Production
Aggregates sales-production balance meeting: sales & production forecast update
Independent stock take (incl. cycle count) by non-stock owner (e.g. Finance)
Cycle count scope completeness with site manager validation
Zero stock (*)
Consigned stocks evaluation and reconciliation
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Annex: Required frequencies : IN-C070, INV03
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Annex: Required frequencies : INV04
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Annex: Required frequencies : Group Accounting
Standards (IAS) – Implementation by division
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Annex: Gallery
Raw mill
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