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UNIT - 3
Syllabus
1. Inventory Management: Definition of
What is inventory?
1. The amount of material, a company has in
5. Office stationary
6. Maintenance material.
maintenance
Continuous Demand
Uncertainty of Demand
2. Dependent Demand
Component parts of a product
Eg. Tyres for bicycle,
Demand is certain
Types of Inventory
1. Seasonal Inventory: Organizations carry inventory to
2.
3.
4.
5.
Decoupling Inventory
An illustration
1
Stage 1
5
Stage 2
3
7
10
Stage 3
Decoupling Inventory
10
Quantity
Cyclic Stock
Pipeline inventory
L
Time
Safety stock
Q0 Q
2
2
Successive Orders.
2. Two Methods of Inventory Management:
Fixed Order Quantity System or EOQ Model
Periodic Review Model
3. Lead Time. Time between placing an order for
Maximum Stock.
Indicates highest stock level
2.
unexpected demand
3.
4.
Reorder Quantity
Quantity of replacement order
5.
Example
1.
Why Inventories?
1. Inventories are needed because demand and supply
Inventory Management
1. Video Case Study: Inventory
Inventory Costs
1. Unit cost or Unit Purchase Cost: it is usually
Inventory Costs:
Procurement costs or Ordering Cost (Co):
Search and identification of appropriate sources of supply
2. Price negotiation, contracting and purchase order generation
3. Follow-up and receipt of material
4. Eventual stocking in the stores after necessary accounting and
verification
1.
Inventory Costs:
Carrying costs or Holding Cost (Cc or Ch)
This represents the cost of maintaining inventories in the
plant.
It includes the interest on capital engaged
Cost of storage (power/AC/Dust free room), cost of
insurance, security, warehouse rent, taxes, spoilage,
breakage, obsolescence etc.
Depended on quantity of inventory held.
Carrying Cost = Average Inventory x Holding Cost Per
Unit
Larger the ordering quantity, higher will be the carrying
cost
Inventory Costs:
Stock out/Shortage costs or Back Order Cost (Cs)
EOQ Model
Cost of Inventory
Minimum Cost
Economic
Order Qty.
Inventory Costs
The objective of inventory
management team is to
minimize the total annual
inventory cost. A simplified
graphical presentation in
which cost of items,
procurement cost and carrying
cost are depicted.
EOQ = Q* (Size of the order representing std qty of material)
Aggregate of the costs of procuring the inventory and costs of holding inventory are the minimum.
=D
Order quantity
=Q
Co
Inventory carrying cost per unit per unit time = C c
The average inventory carried by an organisation=
Q
2
*
C
*
C
TC(Q) =
o
c +
dTC (Q) Cc Co D
2
dQ
2
Q
The second derivative is positive and hence we obtain the
minimum cost by equating the first derivative to zero.
Denoting EOQ by
Q*,
Q*
Time between orders =
D
D
Q*
Q*
as: Q
2C o D
Cc
Total Inv. Cost (for Q = 30000 Units) = C.D + Co.D/Q + Cc. Q/2
= 0.12 x 125000 + 40 x 125000/ 30000 + 0.25 x 0.12 x 30000/2 = $15,616
Example 2
A manufacturer uses Rs. 10,000 worth of an
item during the year. He has estimated the
ordering costs as Rs 25 per order and carrying
costs as 12.5% of average inventory value.
Find the optimal order size, number of order
per year, time period per order and total cost.
Inventory expressed in terms of cash
Deterministic model with continuous demand and
instantaneous supply
Example 3
1.
2.
14000
50 89
11000
90 +
9000
TC (C= Rs14000)
TC (C= Rs11000)
TC (C= Rs9000)
2CoD
2 25000 200
72.5 ~ 73
Cc
1900
1.
EOQ =
2.
3.
TC (min) = Rs 2337840
EPQ
Qmax
t1
t2
EPQ
Qmax
t1
t2
EPQ
t1 = Duration of Production
Co = Set up cost; Cc = Holding Cost or carrying cost
p= Rate of production or Rate of Supply (item/day)
d= Rate of consumption/ Rate of demand (item/day)
Rate of inventory rise during production (during t1 ) = p- d
Production Qty or Batch size (EPQ) = p . t1
Area under ABC ( p d ).Q
Q max = (p-d) . T1
(t t )
2p
Average Inventory =
1
2.Co.D
Cc
(p
(p d)
production quantity.
Find the minimum annual variable cost.
Time for each production run.
2.D.Co. p
2. 3600 2000 600
EPQ
41570
Cc.( p d )
0.1 (600 100)
Significant Few
Insignificant Many
PARETOs Law
ABC Analysis
Based on the annual value of the item.
2. ABC Always Better Control
3. Procedure:
1.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
UNIT VALUE
(Rs)
30000
450
590
25000
600
4500
400
30
145
2300
9
11
2000
4
120
20
10
80
25
1
ANNUAL
DEMAND
80
1200
400
9
200
15
100
1000
200
12
1500
1000
5
4000
120
500
1000
100
100
1500
CONSUMTION
VALUE (Rs)
2400000
540000
236000
225000
120000
67500
40000
30000
29000
27600
13500
11000
10000
16000
14400
10000
10000
8000
2500
1500
CUMULATIVE
NUMBER OF ITEMS
(%)
0
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
40.00%
45.00%
50.00%
55.00%
60.00%
65.00%
70.00%
75.00%
80.00%
85.00%
90.00%
95.00%
100.00%
CUMULATIVE
VALUE (%)
0.00%
62.96%
77.12%
83.32%
89.22%
92.37%
94.14%
95.19%
95.97%
96.73%
97.46%
97.81%
98.10%
98.36%
98.78%
99.16%
99.42%
99.69%
99.90%
99.96%
100.00%
ABC Classification
A graphical illustration
100%
90%
Class C
Class B
70%
60%
Class A
50%
40%
30%
20%
10%
No. of items (% )
0%
10
%
90
%
80
%
70
%
60
%
50
%
40
%
30
%
20
10
0%
0%
80%
XYZ Classification
On the basis of unit cost of the item
High Unit cost (X Class item)
Medium Unit cost (Y Class item)
Low unit cost (Z Class item)
VED Analysis
1. On the basis of criticality of items
Vital
Essential
Desirable
stock
D Low level of service
FSN Analysis
On the basis of movement of inventory
Fast Moving
Slow Moving
Non-moving
N
S
F
V
E
D