Professional Documents
Culture Documents
1.0 INTRODUCTION
This chapter covers the background information of the case study, the statement of
problem, reasons for the research, the aims or objective of the study, the limitation of the
study, scope of the study and organizational chart. The chapter also contains the definition
manufacturing process. There is the need for organizations to pay due attention to the
service or manufacturing industry, is inevitable. The fact that many companies do not
realize that revenue can be generated from surpluses if they are managed properly is rather
unfortunate. Instead of putting measures in place to reduce the occurrence of surpluses and
to manage them properly so as to derive some monetary value, many companies rather
It is generally perceived that surpluses are waste materials which are of no practical use.
Because of this, when surpluses in particular scraps, occur they are rather discarded or
given out to workers without any monetary rewards. As a result some workers cause
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1.2 STATEMENT OF THE PROBLEM
Many organizations often manage their surpluses poorly and inefficiently since they do not
attach any or much importance to them. This is as a result of lack of knowledge on how to
Again, many organizations do not have qualified employees to draw up right and exact
specifications to meet the needs of the organization. There is therefore the need for the
organization to recruit qualified and professional purchasers who could also help reduce the
not have salvage department where they can house surpluses and in particular scrap
materials arising from day to day activities. Such department will take advantage of
At Metro Mass Transport- Takoradi, workers prefer a lot of surplus materials particularly,
scrapped materials because of the improper management of surplus materials. Also, the
collection and housing practices of surplus materials are inefficient. As a result, surpluses
arising from operations are not organized but, are left on the operation floors. These
materials are either discarded or pilfered by workers for personal use leading to financial
This research work is therefore being undertaking to provide guidelines on how wastage
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1.3 OBJECTIVES OF THE STUDY
To study how surpluses and in particular, scraps are managed in the transport
industry.
To analyse the collection and housing of surplus materials in the transport industry.
To study the problems associated with managing surplus materials and in particular,
To investigate for the disposal of scraps and other surpluses in the transport industry.
To recommend ways through which Metro Mass Transport- Takoradi can effectively
surplus management would call for a thorough examination and evaluation of surplus
Metro Mass Transport –Takoradi has therefore been singled out for special study because it
is one of the largest transport establishment in the country and generates more surpluses
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1.5 LIMITATIONS OF THE STUDY
companies. The researcher had to share his time between normal class work and
was hard to come by. General materials on the subject could be found in the
Because of the limited and insufficient financial resources more extensive study
and site visits could not be done. This however, this could have improved the
It will provide guidelines to transport companies for the efficient disposal of surplus
materials.
It will help the researcher to acquire more knowledge on the management of surplus
materials.
The study also aims to afford Metro Mass Transport-Takoradi, some knowledge on how to
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1.7 ORGANISATION OF THE STUDY
This report is divided in to five chapters. The first chapter deals with the introduction to the
study, statement of problem, objectives of the study, limitations of the study, significant of
study, organisation of the study and history of the study. The second chapter contains the
literature review. The third chapter talks about the organization, which is the subject of the
research. The fourth chapter discusses the research methodology adopted for the study and
observations and findings. The fifth, which is the last chapter, has to do with the
Evidence of plans to build the metropolitansexisted as early as 1845, though the first line
was not completed until July 19, 1900. Following the construction of the Eiffel Tower by
eleven years, this elegant transportation system stole the show, and remains to this day a
In 2005 a new management team in MMT defined the following mission and vision: The mission of
MMT is:
To provide an efficient urban mass transport system in Ghana through the use of buses
To build a dominant, reliable, efficient, safe and affordable yet an economically sustainable mass
transit public bus company in Ghana. MMT also aims to introduce the Bus Rapid Transit System
into Ghana.
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1.9 ORGANIZATION STRUCTURE OF METRO MASS TRANSPORT
CEO
Assistance
Regional Managers
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CHAPTER TWO
LITERATURE REVIEW
2.1 INTRODUCTION
This chapter is a review of the relevant literature to the effective management of surplus
materials. The review will cover the following subheadings or key points:
Definition of Surplus
Management of Surplus
Disposal of Surplus
According to Doubler and Burth (1996), industrial surpluses are defined as those materials,
Fearon (1993), defined surplus as a term used to describe material which is in excess of
reasonable requirement of the organization. It arises because of the errors in the amount
According to Jessop and Morrison (1994), scrap and residues are the waste, used or surplus
materials or parts arising out of the manufacturing process or other activities; for example,
steel and non-ferrous tunings, other scrap metal, rejected components, saw dust, used
Lysons and Gillingham(2003), states that surplus is an omnibus term covering materials or
equipment that are in excess of requirement, no longer useable in their original form, or
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are superseded most of such items can be categorized as “scrap” or obsolete .Scrap refers
to the waste from the production process which may have a salvage value. Obsolete means
that an item has gone out of use or has been superseded by equipment offering enhanced
Doubler and Burth (1996), states that scrap or surplus typically originates from sources
like:
Some surpluses or waste from production process is inevitable. Not all production materials
are wholly consumed in most transport establishments. Most of the time, residues are left
This excess called scrap must be disposed of as surplus. It is impossible to eliminate this
kind of surplus; however, with intelligent planning and effective production control, it
could be minimized. Surpluses also result from the inefficient use of production materials
or machinery as well as careless and poor purchasing. This type of surplus is termed as
Obviously, the least cost methods of controlling surplus of all types are to eliminate them at
the source and this is why cost reduction programmes that eliminate surpluses before they
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In the view of fearon (1993), surpluses arising from waste are materials or supplies, which
have been changed during the production process and which through carelessness, faulty
production method, poor handling or other causes have been spoiled, broken or otherwise
rendered unfit for further use or reclamation. This definition is not entirely true.
There is a form of waste which is not as a result of obsolescence and yet not as a result of
carelessness or poor handling. Waste for example, may occur by the fact that the material is
unforeseen chemical action. In some instances, waste can be defined as the residue of
materials which result from the normal manufacturing process and which has no economic
value.
An example is the smoke produced by burning fuel. In theory, waste should never exist.
However, there may never be a time where waste will be eliminated from every production
activity. All efforts must be made to reduce waste to the lowest possible point. Its reduction
can be brought without in many ways such as installation of new processes and improved
production layout.
According to Doubler and Burth (1996), it is unreasonable to expect that sales forecasting
and planning well always be accurate. In case of over anticipation, materials excess above
actual requirement inevitably results. An automobile company for instance may anticipate
that customers prefer seats made of real leather for they will be willing to pay extra
charges. Time will prove however that most customers prefer imitated leather at no
additional cost and this leaves the manufacturer with a surplus of real leather that must be
disposed of.
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Also, changes occur constantly in the designs and specification of fast moving
In addition, production planning takes place well in advance of the time production process
actually begins. At any time prior to the beginning of production or manufacturing process,
either technical or product changes can completely alter the schedule of materials required
for any specific production run. Even after production has taking of, changes in highly
Moreover, the ease with which technical advancement can generate surpluses is highlighted
by the single fact that in any firms today, over 50% of the products they sell or use did not
To add to, excessive forward buying is another common source of surplus materials. Some
firms forward buy only under specific economic circumstances; others forward buy as a
matter of routine company policy. Regardless of the reason for using this method of
Doubler and Burth go further to state that planned over buying and over production
represents still other sources of surplus stocks. Some firms such as machinery and
automobile manufacturers produce more parts for specific models of equipments and
automobiles than they may sell because of what is called ‘the life of time’ problem.
supply of certain replacement parts for new cars while the production line for these cars is
still in operation and pay for their storage for as long as the manufacturer accepts the
responsibly of furnishing replacement parts for this model than it is to pay the high start up
cost, entailed in re-establishment production facilities for the same parts some years later.
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Furthermore any warehousing operation regardless of how efficiently it is managed can
also encounter some surpluses due to breakages, deterioration and errors on record keeping.
According to Fearon (1993), excessive or surplus material is that stock which is in excess
Such materials may be handled in various ways, in some cases, it may be desirable merely
costs are not expensive and if there is reasonable expectation that the material will be
require in future. Occasionally, it may be substituted for more active material or if the
company operates a number of plants, it may be possible to transfer the excesses to another
plant. There are times however, when these conditions do not exist and when fairly prompt
sale is desirable.
Fearon goes on to state further that another source of excess material usually appears on the
follows:
“All new materials for a specific purpose on order and not used on the project in
question constitute an inventory and must be treated as such. As soon as the work is
completed, all new and un-used materials should be transferred immediately to the custody
of the stores department. The original cost of the material should be charged to
“reclamation stores”, which is an unclassified segment of the stores accounts and credited
to the property order on authorization. Provision is also made for the proper accounting of
used materials credited resulting from demolishing work carried out in conjunction with
construction projects.
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Fearon states in addition that, in the case of a large manufacturing company, if the sales
department has definitely obligated the company to produce a certain quantity of an item or
has set up a sales budget for that quantity and has been accepted by management, and later
finds itself unable to sell all the items produced, the losses sustained on the excess
materials are charged to those particular items or sales classification. The same practice is
excess material. This company feels that the loss should not be absorbed generally or
In the words of Doubler and Burth (1996), all machines, tools and equipment at a point in
their life become surplus for one or two basic reasons. They wear out or they become
machines and tool hardly wear out, more frequently; they are replaced because they have
In addition to machine and tools, plants and equipment, most firms also have a large capital
investment in office equipment and in the physical plant itself. Competent management
makes every practical effort to extend the life of the firm’s equipment as long as possible
but, ultimately, because of obsolescence replacement of all capital assets even buildings
become mandatory.
In the view of Fearon (1993), obsolete materials differ from excess stock in that where as
the latter presumably could be consumed at some future date; the former is unlikely to be
ever used inside the organization, which purchased it. For example, typewriter ribbons in a
store become obsolete when the typewriters are replaced with computers. Materials become
obsolete as a result of a charge in the production process or when some better materials are
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substituted for that, which was originally in use. Once a material has been declared
obsolete, it is wise to dispose it of for the best price that can be obtained.
user, this does not mean that it is obsolete for others. An airline may decide to discontinue
using a certain type of aeroplane. This action makes not only the plane but also the repair
and maintenance part inventory obsolete. Both may have a substantial value to order
In the remainder of this chapter, the term surplus is used inclusively to indicate all classes
of scrap, spoiled materials or obsolete materials that still have economic worth.
Fearon (1993), states that the management of surplus is sometimes treated as a secondary
product. The surpluses originating as by-products of this process are often regarded as a
necessary nuisance to handle as quickly as possible. It is estimated that less than one third
of all United State companies give adequate attention to the possible economic benefit of
According to Fearon, they are not often thought of as a source of supplementary income.
Their value is seldom ever shown as a separate item on a company’s income statement or
balance sheet. Usually, the income they generate is buried in ‘the other incomes’ category
Moreover, since the variety of surplus is great and the amount of each type is likely to be
relatively small the seller does not usually become an expert in the business. In fact, surplus
materials are one of the few items in the world of business about which the buyer is
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2.5 PURCHASING AND SURPLUS
In the words of Doubler and Burth (1996), the material cycle is not complete until all
surplus materials are disposed of in the most productive manner. Consequently, in firms
with material management department, the investment recovery function often reports to
the firm’s materials manager. In some operations having large dollar surpluses, however,
the investment-recovering unit reports directly to the plants manager or staff assistance.
Doubler and Burth states, however, that in a majority of cases the investment recovery unit
is assigned to the purchasing department. The reason for this is the fact that usually no
other department in the firm is as well qualify to perform the task. The professional and
managerial skills required for a successful disposal operation are also required to do a good
materials, their market and related operating practices as the purchasing department.
Doubler and Burth states feather more that the purchasing department routinely buys a
large amount of raw materials, components parts, and equipment. It has knowledge about
whose makes these, what other firm use them, how they are used in its own firm, and how
much they cost. This is the precise knowledge needed to sell surpluses of these materials
successfully.
Also, a relatively large number of buyers in the metal industries regularly buy some form
of scraps or other surplus materials for their own manufacturing purposes. In situations like
this, purchasing personnel are particularly knowledgeable about the market in question.
Daily contact with industry representatives, coupled with the reading of purchasing and
trade journals, keeps them informed of surplus trends in a variety of markets. Additionally,
buyers frequently sell a significant portion of their firms; surpluses back to the suppliers
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2.6 INVESTMENT RECOVERING OR SALVAGE DEPARTMENT
According to Doubler and Burt (1996), some firms identify the operating group as their
‘salvage and reclamation’ unit. This function has grown in importance in most firms,
however, many have expanded and sophisticated its level of activity-and have graced the
operation with a new and more appropriate little, the investment recovering department.
Doubler and Burth states that whatever the unit is called, nearly all-manufacturing firms
should have such a functional activity organized and in operation. Depending on the
quantity and value, of the salvageable material involved, the unit can operate either on a
full or part – time basis. Many small firms, unfortunately, fail to establish such an operating
unit simply because they believe their volume of surplus does not justify a full –time
operation.
Assume that an obsolete motor generator is set to be disposed of. If there were no salvage
operation, the department head would dispose of the equipment “as is”. With the existence
of salvage operation, the first determination to be made would be whether the machine
could be sold as an operating machine, either in its present condition or after some minor
repair work was done. If it could not be sold as an operating machine, the second
segregation it into its component parts and/or into its various kinds of metals, such as
In the view of Doubler and Burth the component parts of some used machines can be
valued either for stock purposes or for sale. If the decision is against disassembly, the
machine will be sold “as is” for its scrap metal value. Each of the alternatives will produce
different net revenue. Selling the machine in operating condition usually produces the
greatest return, while selling it “as is” for scrap produces the least. Some firms with high –
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dollar value surplus include in their investment recovery department recycling or recovery
Furthermore according to Doubler and Burth, overall company salvage expenses frequently
can be reduced greatly by pre-planning and instituting simple operating procedures. For
example, sorting surplus metals by type can often be accomplished inexpensively simply
by providing suitable marked containers at the point of accumulation. This easy procedure
increases scrap value. For example, if high- carbon- steel cutting tools are mixed with less
expensive grades of metal scrap, the money realized from selling the mixed as a single lot
will be considerably less than that which will result from selling the cutting tools as one lot
and the remainder of the scrap as another. To simplify sorting of this type, barrels of
different collectors can be used for different kinds of scrap metals. Similarly, surplus paper,
cardboard and similar surplus materials should be segregated during accumulation by using
the method that will bring the highest selling price. An investment recovery unit typically
handles all three kinds of surplus: scrap, surplus stock and surplus equipment.
According to Baily, Jessop, Farmer and Jones (1994), when considering how to dispose of
(a) Can the item be cannibalized for useful part prior to scraping?
(b) Can we sell the item in the market place rather than as scrap? (E.g. Back to the
(c) If we are to sell materials as scrap, can we get a better price if we segregate by type
(d) Can we come into agreement with a merchant whereby he provides skips/
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Bailey, Jessop, Farmer and Jones (1996) states that, the cost associated with disposing of
materials needs to be kept in mind when examining the issues involved. It makes no sense
to install some sophisticated scrap system if the cost of doing so is greater than the money
received. The various ways in which surplus materials are disposed of influence the rate of
return. In the following paragraphs, the various disposal avenues are discussed.
According to Fearon (1996), the organization has to determine whether the material can be
reclaimed or modify for use by welding. Welding has become a very important factor in
advantageously disposing of materials. Defective and spoiled castings and fabricated metal
parts can be reclaimed at a tittle expense; short ends of bar stock, pipe, and so on can be
welded into working lengths; and worn or broken jigs, fixtures, and machine parts can be
reduced in size by either the arc or acetylene cutting process. Or, perhaps a steel washer
could be stamped out of a piece of scrap (referred to as off-fall) which is normal out put of
the production process. Precious metal scraps often is shipped to a precious metal refiner,
who processes it into its original form and returns it for use as a raw material, charging the
The institute of scrap recycling industries and the Environmental protection agency of U S
forecast that, by the mid-1990s, the United States will be recycling 50 percent of the
aluminum; 40 percent of the steel; and 20 percent of the wood, leather, textile, and rubber
needed for new product manufacturing. One of the problems faced by purchasers is the
tendency to coat, bond, or blend materials in such a way that they become non recyclable in
the future.
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2.7.2 RETURN TO SUPPLIER
In the word of Doubler and Burth (1996), if the surplus material cannot be used within the
firm, the return to supplier method of disposal is generally the next best method. Suppliers
typically allow the return of both new and used surpluses as a courtesy of good accounts.
Saleable materials returned from inventory are traditionally accepted at the original cost,
Since different firms have different level of technical requirement, suppliers can frequently
resell even obsolete inventory items at full price. Scrap metals can sometimes be retuned to
suppliers, depending on the size of the buyers’ account, the metal involved, degree of
contamination, and the current economics of the scrap market. When scrap is scarce, many
suppliers routinely require the return of scrap as a precondition of further sales. Particular
attention should be paid to the so-called exotic metals, which include most non-ferrous
metals, alloy steels, and tool steels. Usually these metals can be sold to the supplier at
prices much higher than are attainable in the open market. Supplier policies regarding the
return of used equipment to the manufacturer or dealer from whom it was purchased vary
widely with the economics of the used equipment market and the sales policies.
In the wards of Fearon (1993), return to supplier means that the item can be returned to the
manufacturer or supplier from whom it was purchased, either for cash or for credit on the
other latter purchases. Large quantity purchasers sell a great deal of steel scrap directly
back to the mills, which uses it as raw material in the steel production process. Normally,
the firm using this disposal avenue must be a large consumer. In the case of surplus (new)
inventory items, the original vendor may be willing to allow full credit on returned items.
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2.7.3 SELLING TO OTHER USERS OR FIRMS
According to Doubler and Burth (1996), some companies sell surplus materials and
equipment directly to other firms. Sales of equipment to other firms depend primarily on
the conditions of the equipment pricing conditions and the availability of similar equipment
from other sources. Equipment sales made directly to a user typically resulted in a better
Sales of production surpluses are most profitable when the surplus of one company is the
raw material of another. For example, if a firm can sell its waste paper back to the paper
mill, it generally will get the highest price and cause the least pollution.
In Fearon’s view (1993), the company would have to determine whether any other
manufacturers can use the material either “as is”, or with economical modification. It
should be noted that sales can often be made direct to another user who may be able to use
a disposal item in lieu of raw material they currently are buying. Or, one firm’s surplus or
obsolete equipment may solve another firm’s equipment requirement nicely. A good
example of this is the market, which has existed for year for DC-3 aircraft, which are
obsolete for one air carrier and are bought for use by supplement or commuter airline.
In some cases and particularly prevalent in public agencies, surplus or obsolete equipment
and vehicles are sold at public auction. Some companies permit employees to buy, as part
of their employee relations programme, used equipment or surplus materials at a pre set
price. If this is than, adequate control should be established to ensure that the returns to the
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2.7.4 SALE TO INTERMEDIARIES
According to Doubler and Burth (1996), dealers or brokers are specialized intermediaries
who collect, sort and process surplus materials. Surplus dealers and brokers (referred to as
dealers) constitute an excellent outlet for surplus materials. When a firm advertises surplus
materials for sale, dealers often respond. Transactions with dealers are usually “where is, as
is”, and most of the time they are for cash. Surplus machines tool dealers, for example,
cooperate in two ways: by auction, which usually involves selling a plant’s entire
Doubler and Burth states furthermore that for auctions, the dealer receives a commission
and seldom does more to the equipment than show it to bidders. For small lot transactions,
however, the dealer pays the owner cash, and then often reconditions or rebuilds machine
tools before selling them. Normally, it is not profitable for the original owner to recondition
According to Fearon (1993), if no buyer or user can be found for the item, the firm may
have to destroy or bury it. This can be very expensive because of the landfill shortage and
caution should be taken to ensure that disposal methods for dangerous materials do not
recyclable products, capital assets and surplus materials. In some instances a firm may
deduction. Since the tax aspect of such contribution is complex, the advice of the tax
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counsel should be obtained as part of the decision making process. A number of non-profit
According to Doubler and Burth (1996), many firms make it a practice to sell both the
products they manufacture and their surpluses to their employees. If the surpluses are the
result of over stocking or obsolescence and the materials are new or good condition, or if
they are odds and ends of scrap desired by “do-it yourself” employees, this can be a
satisfactory method of disposal. On the other hand, if the surpluses are not in fully
satisfactory condition, such sales, regardless of their attractive prices can create resentment
in employees towards their employers. Used autobiles can be an especially dangerous item
Doubler and Burth state further that, because of the numerous potential disadvantages
involved, many sophisticated firms will not sell used surpluses (especially equipment) to
their employees. Beside possible dissatisfaction, selling to their employees often entails
Also, high administrative costs have caused some firm to set minimum dollar amount for
sales to employees. Other firms, to avoid administrative cost give their employees surplus
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2.7.7 SELLING BY CONTRACT
In the words of Doubler and Burth (1996), some contractual considerations apply to the
three major categories of materials that are sold as surplus. Scraps metals, depending on
existing economic conditions are best disposed of by either a short or a long-term contract
made with a local scrap dealer. The dealer getting the contract should be selected after an
investigation of at least three dealers. Because of the breadth of scrap market activities, a
more capable dealers who will compete vigorously for the business.
Doubler and Burth (1996) states further that; the highly competitive nature of the scrap
business usually keeps the variation in bid prices within a narrow range. Local dealers have
an operating and transportation advantage over more distant competitors; also, they can
provide more frequent pick ups and more specialized contract service. Also, publish market
prices are available for many variety of scrap, and these prices are frequently used as the
basis for long-term contract prices. Bid prices are normally used for short-term contract
prices.
Furthermore surplus stock, that cannot be return to the supplier, is best disposed of by sell
to jobbers or secondhand dealers. Such sales are most frequently made on a competitive bid
In addition, Doubler and Burth states that intense competition is traditionally developed
after a firm acquires a select group of dealers who are interested in bidding for its surplus
equipment on a continuing basis. Fixed prices to dealers are satisfactory when a selling
firm is sure of the equipment’s faire selling price. Auction is frequently used as a quick and
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advertisements in trade journals or trade papers prove effective in selling this category of
surplus.
According to Fearon (1993), disposal is still a managerial problem since most items can be
disposed of profitably by use of imagination. The following examples are from a large
forest product company, which acquired a logging –lumber- veneer -flooring operation that
The new manager called a meeting of all salaried personnel at which he stressed two major
points.
(a) “We don’t have any problem only opportunities to solve a few difficulties.”
(b) “There is no such thing as junk or waste because there is a buyer for everything at
He concluded by telling the staff he expected them to provide him with the means of
profitably disposing of all by-products within two months. The following is a partial list
Two years before the takeover, the state department of lands and feretory of
UnitedState had insisted that some areas be “clean –cut” and reseeded to birch, balsam
fir and spruce which was just being cut and left to rot. A visit to a news print company
resulted in an offer of $26, per cord for this pulpwood delivered to their plant
contractors were hired to cut and deliver it for $22, resulting in a profit of $4 per cord to
the company, plus100% savings on the former cost of cutting the spruce and balsam fir.
A trucker had been hired to carry away veneer “cores”. A gang saw was installed to cut
then into boards, which were automatically the right length for crating veneer, saving
the veneer mill from having to buy crating materials from the sawmill. Surplus “cores”
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were treated and sold as ornamental fence post at $1 each. A plant visit to a fine paper
manufacturer resulted in an offer of $28 per ton for hardwood chips from the veneer
and flooring mills which previously had beer damped in saw dust pit.
Cut offs from the flooring mill, which had formerly been thrown into the sawdust pit,
were shipped some distance for $40 per ton (delivered) to a manufacturer of hard wood
floor tiles.
Fearon states furthermore that, slabs from the sawmill, which had formerly been
chipped and damped in the sawdust pit, were end- cut and sold to a distributor who
stored then for a year (to air dry) and then resold them to campers for firewood over a
radius of about 50mills. He bought them for $4 per “estimated cord” (and made a
killing by selling them for about $32 per cord). This distributor initiated negotiations to
cut up the “hash” for the same purpose. This would be pure windfall profit and would
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CHAPTER THREE
RESEARCH METHODOLOGY
3.0 INTRODUCTION
In the proceeding chapter which is the review of the relevant literature to the effective
management of surplus materials the researcher examined different subjects and issues as
discussed by various authors. The salient issues reviewed in that chapter included the
generation of surplus, the disposal of surpluses and how revenue is generated from
surpluses. It was observed that to reduce wastage, there is the necessity to develop the
This chapter focuses attention on the research methodology and also explains the method
employed in gathering and collecting of data. It further identified the process of arriving at
solution to the problem and this providing basis for action based on planned, systematic
3.1 METHODOLOGY
The methodology part comprises the research design, study area, sources of data, target
population and the sampling technique used in attaining the objective of this research.
There was as well the use of qualitative and evaluative analysis in the methodology to
assist the researcher to have a first-hand interpretation of the data collected to make
For the purpose of the research work, the researcher designed the research in order to suit
the objectives of the research. The researcher employed a research design that would best
answer the research questions that governs the study. The researcher then used both
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assessment and evaluation, since the researcher need to find all facts pertaining to the study
that exist at a point in time and also make judgment about the effectiveness, relevance,
For the purpose of the study, the researcher limited himself to employees of Metro Mass
Transport. The total population chosen for the study is fifty[50] and out of this number a
sample of thirty [30] was selected and served with questionnaires and the respondents was
made up of twelve [12] top management, ten [10] middle management and eight [8] lower
Due to the nature of the research work, the researcher thus considered the use of non-
probability sampling method in the acquisition of information from selected sample of the
study population. This eased the researcher in his data collection and also assisted in the
The researcher as well focused much on the use of purposive sampling to help the
researcher select the appropriate sample for the research. The sole objective of the use of
purposive sampling is to focus on particular characteristic of the target population that were
of interest and best motivated and enabled in the answering of the research questions.
Purposive sampling provided the researcher with several justifications to make necessary
generalization for the sample that was studied. But despite its merits, the use of purposive
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3.1.4 SOURCE OF DATA
The data for this study were obtained from both primary and secondary source. The
primary source enabled the researcher to acquire first-hand data and materials on the issue
under study.
The primary data were acquired through the use of questionnaires, informal interviews as
well as personal observation and was complemented by secondary data from publication,
internet, etc.
The secondary source was extensively made use of in the literature review of the report.
The secondary data was of profound use to the researcher which actually enabled him to
look for and made enquires to top information for this work.
Similarly, it broadened the researcher’s slope of purpose which helped the researcher in
The researcher used both the primary and secondary method of data collection to acquire
Primary data is the original and first-hand information gathered and recorded for the
Due to the nature and scope of the population the researcher considered using interviews,
questionnaires and as well focused on group discussion in assembling and gathering of data
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QUESTIONNAIRES
As a major source of obtaining data, set of clear questions were defined to reflect the
problem and objective of the research work. The questions consisted of closed-ended and
INFORMAL INTERVIEW
In line with this, the researcher had face-to-face interviews with respondent who
completed the prepared questionnaires that the researcher used. The interaction
offered the researcher the chance to raise a whole lot of issues for clarification
PERSONALOBSERVATION
Personal observation was used in recording all activities at the organization which pertains
to the research and of which seek to suit the research objectives. Employees concerning the
topic were systematically observed under disguise. This avoiding the tendency of the
The secondary data collection placed much emphasis on the use of the literature review
which was used to capture a lot of information about the research topic. The literature
review was also considered under the secondary data since it contains detailed research
Also articles, books, internet, journals and other study objects that capture information to
the related problem will be considered for gathering such data for the studies.
28
3.1.6 PILOT STUDIES
A pilot study was conducted on ten employees at the stores section and scraps departments
and two (2) from the management board of Metro Mass Transport. This was done to ensure
Questions were asked in the form of questionnaires for which respondents were given the
pace to air their views and perceptions about the project work by responding to questions
provided in the questionnaire. The questionnaires in some cases were also used as
interview guide, especially for the staff who had no time to answer questions which was
given in writings.
Interview guide was used in the pilot study to have a close relation with respondents to
explain complex questions and clarify all cumbersome issues that would pose out.
Hence, the pilot studies assisted the researcher to test, discover and solve problems before
the full implementations on the research activity and administration of the questionnaires to
target population.
3.1.7 TRIANGULATION
There was the need to ensure validity and reliability of the data. Both questionnaire and
interview employed in the research activity provided the same result. The researcher used
questionnaire to acquire detailed information from the respondents and used interviews to
clarify some unclear and imprecise responses. This ensured validity and reliability of
responses from respondents and also proved the efficient and effective use of the research
instrument employed.
29
3.1.8 DATA ANALYSIS PROCEDURES
The method used to analyze the data collected was the description approach, statistical
table were drawn based on percentage corresponding absolute figures. They were prepared
after the questionnaires had been collected and analyzed, and the analysis was based on
The qualitative analysis gave detailed descriptions and explanations of the phenomenon
Evaluative analysis gave or assigned values and figures to describe the facts and data
gained and such the analysis was based on examination and judgment of the values
gathered.
The data was analyzed based on the research questions and data collected from the research
question was analyzed by the use of tables. This made the presentation concise and
accurate for anybody to decipher the interpretations. It was also used to facilitate the
understanding of complex numerical data. in addition, the analysis are intended to attract
attention to produce pleasing appearance and make them easier for readers to understand
30
CHAPTER FOUR
4.0 INTRODUCTION
In the preceding chapter which is scope of the study, attention was focused on the history,
activities and current state of the organization which is the subject of the research.
This chapter is a discussion of the various research tools employed for the study. The
researcher also analyses the information that was gathered from the research questions and
Before the researcher goes out to analyze questionnaire responses, it is important to set out
the decision rule. The total population chosen for the study was 50 and out of this number a
sample of 30 was selected and served with questionnaires. This represents 60% of the total
31
QUESTION 1
The rational behind this question was to ascertain the sources of surplus.
140
Number of Percentage
respondents %
120
100
80
60
Percentages
40 Number of Respondents
20
0
es ts ps ce l
ta
ag Cu cra cen To
m S
Da Off ol
es
s
ob
Damages
4 13
Off cuts
2 7
Scraps
18 60
Obsolescence
6 20
Total
30 100
Source: Author's field survey 2013
When the question asked on ''how surplus occur in our establishment?'' 4 respondents
representing 13% of the total respondents indicated that surpluses occurred through
damages, 2 respondents representing 7% indicated that surplus were through off cuts, 18
respondents representing 60% were through scraps and the remaining 20% attributed to
32
QUESTION 2
Number of Percentage
140
respondents %
120
100
80
60
Percentages
40
Number of Respondents
20
0
ls s ts l
ria m ar ta
e Il te P To
at ta en
t
M pi n
Ra
w Ca po
om
C
Raw materials
5 17
Capital items
20 66
Component parts
5 17
Total
30 100
Source Author's field survey 2013
When question was asked on" what type of input do you used in your organization?"5
33
QUESTION 3
This question was posed because every organization that generates surpluses especially
Number of Percentag
140
respondent e %
120 s
100
80
Percentage
Number of respondant
60
40
20
0
Yes No Total
Yes -
-
No 1
30 00
Total
30 100
Source Author's field survey 2013
When the question was asked '' Do you have a storage point for surpluses?'' none of the
respondents answered yes but 30 respondents representing 100% of the total respondents
answered No. This entails that respondents who answered No dominated the entire survey
34
QUESTION 4
This question was asked to enquire of how fast or efficiently work is done.
Manual handling increases the rate of damages and mechanical handling reduces the rate of
damages.
Number of Percentage
140
respondent %
120 s
100
80
Percentages
60 Number of respondant
40
20
0
Manual Mechanical Total
Manual
11 37
Mechanical 6
19 3
Total 1
30 00
Source Author's field survey 2013
When the question was asked on ''How items or products were handled?'' 11 respondents
representing 37% of the total respondents agreed to the manual option whiles 19
respondents representing 63% agreed to the mechanical option of the study respectively.
this explains that the mechanical option dominated the entire survey conducted. This is
35
QUESTION 5
This question was asked because segregated scraps often have greater money than non-
segregated scraps.
Number of Percentage
140 respondent %
120 s
100
80
Percentage
Number of respondent
60
40
20
0
Yes No Total
Yes 10
30 0
No -
-
Total 1
30 00
Source Author's field survey 2013
representing 100% answered Yes whiles none of the respondents answered No representing
0% of the total respondents. This explains that Yes alternative dominated the entire survey
36
QUESTION 6
This question was asked to ascertain the method of disposal that was employed in the
organisation.
Number of Percentag
140
120 respondents (%)
100
80
60
40
20 Percentages
0 Number of respondent
rs rs s l
lie r m
ke ee ta
p e fi ro loy To
p th b p
su in or em
to th s to
rn wi ale
r
es
etu ed e u
R Us
d ss
s to eei
l e Fr
Sa
Return to suppliers
2 7
Used within the firma
10 3
Sale to dealers or brokers
10 33
Free issue to employees
8 27
Total
30 100
TABLE 4.1. 6: Methods of disposal
When the question was asked on what methods of disposal were employed? 2 respondents
representing 30% answered that it should be used within the firm, 10 respondents
representing 27% answered that it should be issued free to employees respectively. This is
37
QUESTION 7
This question was to find out the department or section that has responsibility for surplus
disposal.
Number of Percentage
140
respondents (%)
120
100
80
60
Percentage
40 Number of respondents
20
0
er r nt rs l
as ee ta
h on u lta the To
rc cti ns O
Pu Au co
p
ra
Sc
Purchaser -
-
Auctioneer -
-
Scrap consultant
10 33
Others
20 67
Total
30 100
Source Author's field survey 2013
When the question was asked on who is responsible for disposal of surplus. None of the
respondent representing 0% answered to the purchaser option, also none of the respondent
answered to the auctioneer option,10 respondents representing 33% answered to the scrap
38
consultant of the total respondents and 20 respondents representing 67% answered to others
respectively.
QUESTION 8
This question was asked because the sort of training given will affect the way surpluses are
managed
Number of Percentage %
140
respondents
120
100
80 Percentage %
60 Number of re-
spondents
40
20
0
Yes No Total
Yes 30 100
No - -
Total 30 100
When the question was asked on "Does management offer training opportunities?"30
respondents representing 100% answered Yes whiles none of the respondent answered No
representing 0% of the total respondents. This explains that those who answered Yes
39
QUESTION 9
This was asked to know how equipped and capable the staff is in managing surpluses.
Number of Percentage
100
respondents (%)
80
60
40
20
Percentage (%)
0
Number of respondents
ls ps s
eria cra ts e
m
at of
s y
fm n ngs
i
go atio rd
lin eg ec
o
nd gr r
Ha Se p er
P ro
Handling of materials
22 73
Segregation of scraps
3 10
Proper recording systems
5 17
Total
30 100
Source Author's field survey 2013
When the question was asked on" what type of training is offered?"22 respondents
40
QUESTION 10
This question was asked to determine whether the expenses incurred exceed sales value of
surplus.
Number of Percentage
80 respondents (%)
70
60
50
40
30 Percentage (%)
20 Number of respondents
10
0
g rt st
usin spo co
ho n on
of tra ati
st of eg
o st gr
C Co Se
Cost of housing
18 60
Cost of transport -
-
Segregation cost
2 7
Handling cost
10 33
Total
30 100
Source Author's field survey 2013
When the question was asked on "what are some of the expenses incurred in management
segregation cost and 10 respondents representing 33% indicated handling cost respectively.
41
4.4 SUMMARY OF RESEARCH FINDINGS
The objective of the study was to find out how surplus materials can be managed
effectively in the transport industry. The researcher in the course of the study made some
findings. The findings have been analyzed and enumerated below. Data was obtained
4.5 SUMMARY
In this chapter various research tools adopted were discussed. The researcher also sort to
analyse the findings which were critical to the attainment of the stated objectives and drew
conclusion for them. The next and last chapter, the whole research work will be
Mass Transport- Takoradi, which it is hoped will help them managed and dispose of
42
CHAPTER FIVE
5.0 INTRODUCTION
The previous chapter sought to analyze information that was gathered from the research
questionnaire. The researcher went further to examine ten (10) key that were critical to the
achievement of the objectives that were stated in the introduction to the study. Relevant
conclusions were drawn from the ten selected key questions. The various tools adopted for
In this last and final chapter, the researcher presents a summary of the whole research
work. This section will move on to further make suggestions and recommendations that
will aid the management of Metro Mass Transport- Takoradi to effectively manage and
dispose of surpluses
5.1 SUMMARY
This research work is being presented in partial fulfilment of the requirement for the award
of the Higher National Diploma (HND). The study consists of five (5) chapters. The
introductory chapter deals with the statement of the problem, objectives of the study, the
scope of the study, constraints and the plan of work and the significance of the study.
The review of related literature as presented in chapter two provides details of the various
textbooks that the researcher consulted in undertaking the study. Chapter three is a
The data gathering instrument used for carrying out this research work appears in chapter
four. It consists of the major research tools which is the primary research method and
43
secondary research method. The strength and weaknesses of these tools were also
enumerated. The chapter also contains the analysis of findings from research
questionnaires.
Here the researcher identified 10 key questions which were relevant to the objectives of the
The final chapter is about the summary, conclusions and recommendations. The section
summarizes the whole research work and makes conclusions based on which
5.2 CONCLUSION
The following paragraphs deal with the conclusions that were drawn from the ten key
OCCURANCE OF SURPLUS
The research questionnaire revealed that surpluses do occur in the company through
damages, obsolescence and residues of materials such as oil and lubricants. The researcher
noticed that, the major source of surplus is through scrap and obsolescence.
STORAGE OF SURPLUS
It was revealed that the company does not have a point specifically designated to the
44
HANDLING OF SURPLUS
The research questionnaire revealed that both manual and mechanical means of handling
are employed. It was however observed that the mechanical handling equipment is not for
the salvage section. And that the section relies on other department for these devices which
DISPOSAL OF SURPLUS
The researcher found out that, there are various means through which scrap are disposed at
Metro Mass Transport. The surpluses which result from oils are sometimes given to
workers example, dirty oil. Those that can be reused or needed by other departments are
retained. Example, dirty oil may be used to wash bolt and nuts. The rest of the surplus,
particularly scrap surplus which forms the bulk is sold to dealers or brokers. It was again
realized that certain items are given to workers free of charge. Such items include paint,
The researcher observed that some user department deliberately over specify since they
have the view that the left-over will be given to them freely. It also came to the notice of
the researcher that the prices of scrap surpluses are very low as compared to the prices the
MANAGEMENT OF SURPLUS
A surprising observation that was made was that at Metro Mass Transport a committee is in
charge of management and disposal of surpluses. The researcher was surprised since
45
5.3 RECOMMENDATIONS
This section contains the recommendations that the researcher offers to management based
OCCURRENCE OF SURPLUS
put in proper requisitions for needed materials. Again, the material requirement planning
staff must also be trained well to make the right forecast in their planning to reduce
wastage. The researcher also encourages management to educate the various user
STORAGE OF SURPLUS
The researcher suggests that management should do their possible best to put up a special
storage place so that surpluses generated can be housed to enhanced proper management
It is recommended that supplies staffs are put in charge of scrap surpluses since they are
more equipped by the nature of their work to carry out this duty more efficiently and
The researcher recommended that, since a lot of surplus items at the store are priced based
on tonnage, devices such as weighbridge which will determine the exact tonnage per item
should be provided if possible since this will go a long way to increase revenue through
proper pricing of scrap surpluses. The management must also acquire material handling
46
TRAINING PROGRAMS
The research questionnaire showed that management of Metro Mass Transport does
provide training for the store staff. Notable among such training programme are handling
of materials and safety procedures in handling and disposal of scrap surpluses. This is a
step in the right direction and the researcher encourages management to continue
organizing such training programme for staff that helps with the disposal and management
of scrap surpluses.
DISPOSAL OF SURPLUS
For an effective disposal of surplus, the researcher suggests that management put proper
It was observed that some user department deliberately over specify since they have the
view that the left-over will be given to them freely. Based on this observation, the
researcher recommends management to place a price on these items and not to give them
out freely to workers in order to reduce the rate at which over specifications are made.
It also came to the notice of the researcher that the prices of scrap items are very low when
compared with the prices the dealers and brokers charge on the items on the market. The
ascertain ruling prices so that a more appreciable value can be placed on scrap surpluses.
MANAGEMENT OF SURPLUSES
It is recommended that supplies staffs are put in charge of scrap surpluses since they are
more equipped by the nature of their work to carry out this duty more efficiently and
47
48