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B (2) C D (3)
Total: 48 + 20 + 70 = 138
Inventory Management
Inventory Management
To avoid
stock outs
(Safety Stock To act as a buffer
or Buffer To minimize between various
Stock) the total cost elements of the Supply-
by ordering Chain (Suppliers-
the Economic Producers-Distributors-
Order Wholesalers-Retailers-
Quantity Customers) (Pipeline or
(Cycle Stock) Transit Stock)
Inventory Related Costs
Cost of Goods
Procurement Costs
Ordering Cost
Cost / Order generally fixed
Not dependant on order quantity
- Administrative cost
- Handling
- Transportation
- Inspection of arrivals
Inventory Holding Costs
Costs associated with existence of Inventories
(Supply exceeds demand)
Cost/unit/unit time
iC
(i = inventory carrying cost rate)
Material Just-In-Time
ABC Requirements (JIT)
EOQ Model for
Classification Planning (MRP) Systems
Manufacturers
of Items Systems
Hybrid MRP-JIT
Systems
Category Category Category
A Items B Items C Items
Periodic
Basic Economic Review
Order Quantity System
(EOQ) Model
70 —
60 —
50 —
40 —
30 —
20 —
10 —
0—
10 20 30 40 50 60 70 80 90 100
Percentage of SKUs
ABC Analysis
• Class A
– 5 – 15 % of units (approx.)
– 70 – 80 % of value (approx.)
• Class B
– 30 % of units (approx.)
– 15 % of value (approx.)
• Class C
– 50 – 60 % of units (approx.)
– 5 – 10 % of value (approx.)
Solved Problem 1
Booker’s Book Bindery divides SKUs into three classes,
according to their dollar usage. Calculate the usage
values of the following SKUs and determine which is
most likely to be classified as class A.
Quantity Used Unit Value
SKU Number Description
per Year ($)
1 Boxes 500 3.00
2 Cardboard 18,000 0.02
(square feet)
3 Cover stock 10,000 0.75
4 Glue (gallons) 75 40.00
5 Inside covers 20,000 0.05
6 Reinforcing tape 3,000 0.15
(meters)
7 Signatures 150,000 0.45
Solved Problem 1
SOLUTION
The annual dollar usage for each item is determined by multiplying the
annual usage quantity by the value per unit. As shown in Figure 12.11,
the SKUs are then sorted by annual dollar usage, in declining order.
Finally, A–B and B–C class lines are drawn roughly, according to the
guidelines presented in the text. Here, class A includes only one SKU
(signatures), which represents only 1/7, or 14 percent, of the SKUs but
accounts for 83 percent of annual dollar usage. Class B includes the
next two SKUs, which taken together represent 28 percent of the SKUs
and account for 13 percent of annual dollar usage. The final four SKUs,
class C, represent over half the number of SKUs but only 4 percent of
total annual dollar usage.
Solved Problem 1
Quantity
SKU Unit Value Annual Dollar
Description Used per
Number ($) Usage ($)
Year
1 Boxes 500 3.00 = 1,500
2 Cardboard 18,000 0.02 = 360
(square feet)
3 Cover stock 10,000 0.75 = 7,500
4 Glue (gallons) 75 40.00 = 3,000
5 Inside covers 20,000 0.05 = 1,000
6 Reinforcing tape 3,000 0.15 = 450
(meters)
7 Signatures 150,000 0.45 = 67,500
Total 81,310
Solved Problem 1
Class C
100 – Class B
90 –Class
Percentage of Dollar Value
A
80 –
70 –
60 –
50 –
40 –
30 –
20 –
10 –
0–
10 20 30 40 50 60 70 80 90 100
Percentage of SKUs
Unsolved Problem 1
Lockwood Ind. Is considering the use of ABC analysis to focus on the most
critical SKUs in its inventory. For a random sample of 8 SKUs, following table
shows the annual dollar usage. Rank the SKUs and assign them to A,B or C
class
SKU Dollar Value ($) Annual Usage
1 .01 1200
2 .03 120,000
3 .45 100
4 1.00 44,000
5 4.50 900
6 .90 350
7 .30 70,000
8 1.50 200
Cumulative Cumulative
% %
SKU Descripti Qty Value Dollar Pct of of Dollar of SKUs Class
# on Used/Year Usage Total Value
4 44,000 $1.00 $44,000 60.0% 60.0% 12.5% A
7 70,000 $0.30 $21,000 28.6% 88.7% 25.0% A
5 900 $4.50 $4,050 5.5% 94.2% 37.5% B
2 120,000 $0.03 $3,600 4.9% 99.1% 50.0% B
6 350 $0.90 $315 0.4% 99.5% 62.5% C
8 200 $1.50 $300 0.4% 99.9% 75.0% C
3 100 $0.45 $45 0.1% 100.0% 87.5% C
1 1,200 $0.01 $12 0.0% 100.0% 100.0% C
Total $73,322
SKUs
OBJECTIVE OF ABC ANALYSIS:
Rationalization of Ordering Policies
EQUAL TREATMENT TO ALL
Item no. Annual Consumption Number of Value per order Average inventory
Value (Rs.) Orders
1 60,000 4 15,000 7500
2 4,000 4 1,000 500
3 1,000 4 250 125
Total cost
inventory
carriage
ordering
time Q*
Economic Order Quantity
The lot size, Q, that minimizes total annual inventory
holding and ordering costs
Five assumptions
1. Demand rate is constant and known with certainty
2. No constraints are placed on the size of each lot
3. The only two relevant costs are the inventory holding
cost and the fixed cost per lot for ordering or setup
4. Decisions for one item can be made independently of
decisions for other items
5. The lead time is constant and known with certainty
Calculating EOQ
Receiv Inventory
e order depletion (demand
rate)
Q
On-hand inventory
Q Average
cycle
2 inventory
(units)
1 cycle
Time
Calculating EOQ
• Annual holding cost
Annual holding cost = (Average cycle inventory)
(Unit holding cost)
Total cost
Holding cost
Ordering cost
Q D
C = 2 (H ) + (S)
Q
where
C = total annual cycle-inventory cost
Q = lot size
H = holding cost per unit per year
D = annual demand
S = ordering or setup costs per lot
The Cost of a Lot-Sizing Policy
EXAMPLE 12.1
• A museum of natural history opened a gift shop which operates
52 weeks per year.
• Managing inventories has become a problem.
• Top-selling SKU is a bird feeder.
• Sales are 18 units per week, the supplier charges $60 per unit.
• Ordering cost is $45.
• Annual holding cost is 25 percent of a feeder’s value.
• Management chose a 390-unit lot size.
• What is the annual cycle-inventory cost of the current policy of
using a 390-unit lot size?
• Would a lot size of 468 be better?
The Cost of a Lot-Sizing Policy
SOLUTION
We begin by computing the annual demand and holding cost as
D = (18 units/week)(52 weeks/year) = 936 units
H = 0.25($60/unit) = $15
3000 –
Total Q D
Annual cost (dollars)
2000 –
Q
Holding cost = (H)
2
1000 –
D
Ordering cost = (S)
Lowest Q
cost
| | | | | | | |
0–
50 100 150 200 250 300 350 400
Lot Size (Q)
Best Q Current
(EOQ) Q
Calculating EOQ
• The EOQ formula:
2DS
EOQ =
H
EOQ
TBOEOQ = (12 months/year)
D
Finding the EOQ, Total Cost, TBO
EXAMPLE 12.2
For the bird feeders in Example 12.1, calculate the EOQ and its total
annual cycle-inventory cost. How frequently will orders be placed if
the EOQ is used?
SOLUTION
Using the formulas for EOQ and annual cost, we get
2DS 2(936)(45)
EOQ = = = 74.94 or 75 units
H 15
Finding the EOQ, Total Cost, TBO
Figure shows that the total annual cost is much less than the $3,033 cost
of the current policy of placing 390-unit orders.
Finding the EOQ, Total Cost, TBO
When the EOQ is used, the TBO can be expressed in various
ways for the same time period.
EOQ 75
TBOEOQ = D = = 0.080 year
936
EOQ 75
TBOEOQ = D (12 months/year) = (12) = 0.96 month
936
EOQ 75
TBOEOQ = D (52 weeks/year) = (52) = 4.17 weeks
936
EOQ 75
TBOEOQ = D (365 days/year) = (365) = 29.25 days
936
Application 12.1
Suppose that you are reviewing the inventory policies on an $80
item stocked at a hardware store. The current policy is to replenish
inventory by ordering in lots of 360 units. Additional information is:
SOLUTION
2DS 2(3,120)(30)
EOQ = = = 97 units
H 20
Application 12.1
What is the total annual cost of the current policy (Q = 360), and
how does it compare with the cost with using the EOQ?
SOLUTION
360
TBO360 = (52 weeks per year) = 6 weeks
3,120
97
TBOEOQ = (52 weeks per year) = 1.6 weeks
3,120
Problem 2
Nelson’s Hardware Store stocks a 19.2 volt cordless drill that is a popular
seller. Annual demand is 5,000 units, the ordering cost is $15, and the
inventory holding cost is $4/unit/year.
a. What is the economic order quantity?
b. What is the total annual cost for this inventory item?
Solved Problem 2
SOLUTION
a. The order quantity is
2DS 2(5,000)($15)
EOQ = =
H $4
= 37,500 = 193.65 or 194 drills
b. The total annual cost is
Q D 194 5,000
C = 2 (H) + (S) = ($4) + ($15) = $774.60
Q 2 194
Inventory Control Systems
Nature of demand
Independent demand
Dependent demand
Inventory Control Systems
• Continuous review (Q) system
– Reorder point system (ROP) and fixed
order quantity system
– For independent demand items
– Tracks inventory position (IP)
– Includes scheduled receipts (SR), on-hand
inventory (OH), and back orders (BO)
Inventory position = On-hand inventory + Scheduled receipts
– Backorders
IP = OH + SR – BO
Selecting the Reorder Point
IP IP IP
Order Order Order Order
received received received received
On-hand inventory
Q Q Q
OH OH OH
R
Order Order Order
placed placed placed
L L L Time
TBO TBO TBO
SOLUTION
IP = OH + SR – BO = 10 + 200 – 0 = 210
R = 100
SOLUTION
R = Total demand during lead time = (25)(4) = 100 cases
IP = OH + SR – BO
= 10 + 200 – 0 = 210 cases
Continuous Review Systems
Selecting the reorder point with variable demand and
constant lead time
where
d = average demand per week (or day or months)
L = constant lead time in weeks (or days or months)
Reorder Point
1. Choose an appropriate service-level policy
– Select service level or cycle service level
– Protection interval
σdLT = σ d 2L = σ d L
Probability of stockout
(1.0 – 0.85 = 0.15)
Average
demand
during
lead time R
zσdLT
Finding Safety Stock with a Normal Probability Distribution for an 85 Percent Cycle-
Service Level
Reorder Point for Variable Demand
EXAMPLE
Let us return to the bird feeder in Example.
The EOQ is 75 units. Suppose that the
average demand is 18 units per week with
a standard deviation of 5 units. The lead
time is constant at two weeks. Determine
the safety stock and reorder point if
management wants a 90 percent cycle-
service level.
Reorder Point for Variable Demand
SOLUTION
In this case, σd = 5, d = 18 units, and L = 2 weeks, so
σdLT = σd L = 5 2 = 7.07. Consult the body of the table in the
Normal Distribution appendix for 0.9000, which corresponds to
a 90 percent cycle-service level. The closest number is 0.8997,
which corresponds to 1.2 in the row heading and 0.08 in the
column heading. Adding these values gives a z value of 1.28.
With this information, we calculate the safety stock and reorder
point as follows:
Q D
C= (H) + (S) + (H) (Safety stock)
2 Q
Application 12.5
The Discount Appliance Store uses a continuous review system
(Q system). One of the company’s items has the following
characteristics:
2DS 2(520)(45)
EOQ = = = 62 units
H 12
σdLT = σd L = 8 3 = 14 units
62 520
C = 2 ($12) + 62 ($45) + 8($12) = $845.42
Application 12.5
Suppose that the current policy is Q = 80 and R = 150. What will be the
changes in average cycle inventory and safety stock if your EOQ and R
values are implemented?
Reducing Q from 80 to 62
Cycle inventory reduction = 40 – 31 = 9 units
Safety stock reduction = 120 – 8 = 112 units
Reducing R from 150 to 38
Periodic Review System (P)
Order placed for variable amount after fixed passage
of time
SOLUTION
IP = OH + SR – BO
= 0 + 0 – 5 = –5 sets
T – IP = 400 – (–5) = 405 sets
SOLUTION
IP = OH + SR – BO
= 10 + 200 – 0 = 210
T – IP = 400 – 210 = 190
EOQ 75
P= (52) = (52) = 4.2 or 4 weeks
D 936
B) Suppose that actual demand is 60 bags but that ordering costs are
cut to only $6 by using internet to automate order placing. However, the
buyer does not tell anyone and the EOQ is not adjusted to reflect this
reduction in S. How much higher will total costs be, compared to what
they could be, if EOQ were adjusted
Unsolved # Qn 24
The farmer’s wife is a country store specializing in knickknacks suitable for a
farm house décor. One item experiencing a considerable buying frenzy is a
miniature Holstein cow. Average weekly demand is 30 cows, with a SD of 5
cows. The cost to place a replenishment order is $15 and the holding cost is
$.75/ cow /year. The supplier however is in China. The LT for new orders is 8
weeks, with a SD of 2 weeks. The farmer’s wife which is open only 50 weeks
a year wants to develop a continuous review system for this item with a
cycle service level of 90 percent.
A. Specify the continuous review system for cows. Explain how it would
work in practice
B. What is the total annual cost for the system you develop
Solved Problem 2
Nelson’s Hardware Store stocks a 19.2 volt cordless drill that is a popular
seller. Annual demand is 5,000 units, the ordering cost is $15, and the
inventory holding cost is $4/unit/year.
a. What is the economic order quantity?
b. What is the total annual cost for this inventory item?
SOLUTION
a. The order quantity is
2DS 2(5,000)($15)
EOQ = =
H $4
= 37,500 = 193.65 or 194 drills
b. The total annual cost is
Q D 194 5,000
C = 2 (H) + (S) = ($4) + ($15) = $774.60
Q 2 194
Solved Problem 3
A regional distributor purchases discontinued appliances from
various suppliers and then sells them on demand to retailers in the
region. The distributor operates 5 days per week, 52 weeks per year.
Only when it is open for business can orders be received.
Management wants to reevaluate its current inventory policy, which
calls for order quantities of 440 counter-top mixers. The following
data are estimated for the mixer:
2DS 2(26,000)($35)
EOQ = =
H $9.40
= 193,167 = 440.02 or 440 mixers
Solved Problem 3
The standard deviation of the demand during lead time distribution is
σdLT = σd L = 30 3 = 51.96
Reorder point (R) = Average demand during lead time + Safety stock
= 300 mixers + 73 mixers = 373 mixers
440 26,000
C= ($9.40) + ($35) + ($9.40)(73) = $4,822.38
2 440
EOQ 440
P= (260 days/year) = (260) = 4.4 or 4 days
D 26,000
2DS 2(100,375)($10)
EOQ = =
H $0.30
Q D
C = 2 (H) + Q (S) + (H)(Safety stock)
2,587 100,375
C= ($0.30) + ($10) + ($0.30)(660) = $974.05
2 2,587
Solved Problem 6
Zeke’s Hardware Store sells furnace filters. The cost to place an order to the
distributor is $25 and the annual cost to hold a filter in stock is $2. The
average demand per week for the filters is 32 units, and the store operates
50 weeks per year. The weekly demand for filters has the probability
distribution shown on the left below.
The delivery lead time from the distributor is uncertain and has the
probability distribution shown on the right below.
Suppose Zeke wants to use a P system with P = 6 weeks and a cycle-service
level of 90 percent. What is the appropriate value for T and the associated
annual cost of the system?
Solved Problem 6
24 0.15 1 0.05
28 0.20 2 0.25
32 0.30 3 0.40
36 0.20 4 0.25
40 0.15 5 0.05
Solved Problem 6
SOLUTION
Figure 12.13 contains output from the Demand During the Protection
Interval Simulator from OM Explorer.
Solved Problem 6
Given the desired cycle-service level of 90 percent, the appropriate T
value is 322 units. The simulation estimated the average demand
during the protection interval to be 289 units, consequently the safety
stock is 322 – 289 = 33 units.
The annual cost of this P system is
6(32) 50(32)
C= ($2) + ($25) + (33)($2)
2 6(32)
SOLUTION
Figure 12.14 shows output from the Q System Simulator in
OM Explorer. Only weeks 1 through 13 and weeks 41
through 50 are shown in the figure. The average total cost
per week is $305.62. Notice that no stockouts occurred in
this simulation. These results are dependent on Zeke’s
choices for the reorder point and lot size. It is possible that
stockouts would occur if the simulation were run for more
than 50 weeks.