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Total Number of Subscribers: 464 | |
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Date:17th Febraury 2009 |
Compiled by Mr. M. Sathya Kumar | |
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Internal Audit of an SME (Forging Unit) — Assurance and Consulting Role Background : The Managing Director of a forging manufacturing unit based in Chennai has been in touch with the partner of a Chartered Accountant firm since their chance meeting on a flight from Mumbai to Chennai. They started talking on business issues and the partner of the firm found the Managing Director (MD) to be a progressive person. He therefore suggested to the MD to carry out an internal audit in his manufacturing as the ‘internal audit unit’ would optimise cost and would also help to streamline processes. The Managing Director however felt that as the turnover was only Rs.35 crores, and he controlled most of the operations like procurement, finance, manufacturing, etc., ‘internal audit’ would not yield any significant benefit. The partner suggested that the internal audit be a quarterly feature with 12 days spent by a Chartered Accountant and a semi-qualified staff member, and he himself would be available for three days each quarter. He planned for the staff to carry out process reviews for improvements and he himself would devote time for consulting which would be ‘value added’ and bring out the benefits of internal audit to this Small and Medium Enterprise (SME). The partner of the firm added that the internal audit be carried out for the first quarter and since the MD was initially hesitant, the partner added that all at stake for the MD was the first quarter fees for internal audit and if he was not satisfied, the arrangement would be terminated. In other words, the arrangement was akin to a person going to the doctor for an annual check-up. This first quarter fee would be diagnostic fee for the organisation and assure the MD that the controls were working and all was well. Methodology : Based on the above background, the partner-in-charge of the firm had a meeting with his audit manager to chalk out a plan to achieve the above objectives and ensure that the internal audit service was really beneficial to the SME. The success of the first quarter internal audit would demonstrate the ‘value added’ by internal audit. In the first quarter, it was decided that the team would focus on Procurement, Stores including Inventory, Human Resources and the partner-in-charge would be reviewing the Finance & Accounts. Throughout the internal audit, it was agreed amongst the internal audit team members, that education and awareness for institutionalised systems and procedures including importance of decisions to be taken on scientific basis rather than ‘rule of thumb’ would be emphasised. This is particularly relevant in an SME where the decisions are mainly taken on ‘rule-of-thumb basis’. Based on the internal audit carried out, the following are some of the observations and recommendations : Cost-saving measures identified : 1.0 The organisation had exports of around 20 crores. There was absence of understanding of Forex Risk Management in the organisation. With crores worth of exports which entail inward remittances, high capital expenditure outflow expected in future due to machinery imports was imperative to understand and have a robust Forex Risk Management policy. The organisation was losing out in forex transactions because of lack of awareness of negotiating rates on presentation of documents and at the time of inward remittance with the banker. The rate given by the bank was accepted as the final rate. It was not important as to what rate was given and whether the organisation had been losing out on negotiating better rates — it is important to note here that there was no awareness of the fact that the same could have been negotiated with the bankers, especially, in view of the organisation’s growth in future. Better awareness of the above would have led to cost savings — probable cost savings could have been Rs.3.0 lacs approx. on an annual basis. Better negotiation were required on the margin which bank takes on each transaction. It was later learnt that the spread on inward remittance was around 11 paise which was later renegotiated to 3 paise. The bank was earlier charging the card rate rather than giving the best rate. A process was put in place to verify each inward remittance with the rate being given benchmark against rates from other banks, bank’s dealing room in case of high-value inward remittances and also the rate from specialised agency dealing in forex consulting. The partner also recommended that a workshop by some specialised agency dealing in forex consultancy be arranged for the Finance team for better understanding of forex transactions undertaken by the organisation. 2.0 Insurance — The Company has Marine Transit Policy for all exports. The present exports were of Rs.20 crores last year and are bound to increase on year-to-year basis. The premium paid is 10 paise per Rs.1000 to XYZ Co. Ltd. The claim ratio was zero last year.Since this is a negotiable policy, the company may negotiate it to 2.25 paise per Rs.1000. This will lead to savings of 7.75 paise per Rs.1000 for the export that takes place on yearly basis, which is again a savings of few lacs every year. The management was able to bring down the insurance premium based on absence of claims in the past. 3.0 High interest rate on working capital and term loans : The organisation has a good balance sheet and profit and loss account in terms of profitability and other ratios which are used for basis for lending and deciding interest rates by the bank. The company presently pays interest rate of 11.25% on working capital and term loans, which is much higher than that charged to good organisations. It was suggested that the organisation needs to negotiate with the bank to bring this interest rate down to 9%. The Finance department was not aware of the basis for rating by the bank. With working capital and term loans to be increased to 10 crores, the savings on interest outflow, considering 9% interest, would be again a few lacs per annum. In addition, there existed the necessity to negotiate and get waivers and reduction in rates for Bank Guarantee commission, LC charges and other charges from the bank. Better interaction with the Bank was recommended. The above areas are illustrative examples of observations and recommendations. There were numerous issues in which suggestions were made to improve the controls — for example — Procurement, Stores, Management and Human Resources. Gist of observations in Stores is given below. 4.0 Stores Management : 4.1 On our verification of the returnable goods as on 18-6-2006, we find that for a period since 2003, 75 items have not been returned. 4.2 Minimum and maximum stock levels are not being maintained as a part of the system, but are being maintained in a hard copy (which is subject to revision). 4.3 The system does not prompt for items going below the minimum level of inventory. 4.4 Problems posed due to non-linkage of minimum and maximum stock levels with the system leading to shortages and excess inventory. 4.5 Identification marks need to be placed properly on all consumable items. 4.6 Lack of segregation of duties amongst the Stores department personnel. 4.7 Duplication of work due to maintenance of multiple stock registers. 4.8 Some material indents not signed by the GM — non-compliance with laid-down policy. 4.9 59% of the purchase orders account for only 5% of the total value of purchases. 4.13 No physical verification has been conducted periodically, leading to non-determination of actual loss due to pilferage, if any. 4.14 Minimum time gap between raising of material indent and receipt of material varied from 0 days while the maximum gap is 57 days. This could be rationalised. 5. Review of job work process for Machining and Stores division : 5.1 Policy, procedures need to be documented and approved by the Management, for job work given to the vendors. 5.2 Track sheet needs to be maintained for Stores and Engineering items and material of Machining department goes out for job work charges to the vendor with details of material, time out, delivery date, etc. 5.3 Delivery date to be mentioned on challan, while Stores and Engineering material goes out for job work purposes with vendors. Conclusion : The Managing Director appreciated the efforts of the internal audit team and wanted the internal audit to be carried out bi-monthly. He specially appreciated the approach of the internal audit team in understanding of the business and giving value-added advise which resulted in cost savings. The Managing Director also happened to be the President at the SME Engineering Association at Chennai and promised to propagate the need for such value-added internal audit services by Chartered Accountants to all SMEs. It led the internal auditing function to be elevated to deliver business solutions.
Article by Deepjee Singhal, Manish Pipalia, a renowed Chartered Accountants having expertise in Internal Audit.
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