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Unit13
Unit13
Structure
13.1 13.2 13.3 Introduction Costsassociatedwithinventoriesare InventorymanagementTechniques 13.3.1 DeterminationofStockLevels 13.3.2 Pricingofinventories 13.4 Summary TerminalQuestions AnswertoSAQsandTQs 13.1 Introduction
InventoryManagement
InventoriesarethemostsignificantpartofcurrentaspectsofmostofthefirmsinIndia.Since theyconstituteanimportantelementoftotalcurrentassetsheldbyafirmtheneedtomanage inventoriesefficiently andeffectivelyforensuringoptimalinvestmentininventorycannotbe ignored.Anylapseonthepartofmanagementofafirminmanaginginventoriesmaycausethe failureofthefirm.Themajorobjectivesofinventorymanagementare: a. Maximumsatisfactiontocustomer. b. Minimuminvestmentininventory. c. Achievinglowcostplantoperation. Theseobjectivesconflicteachother.Therefore,ascientificapproachisrequiredtoarriveatan optimalsolutionforearningmaximumprofitoninvestmentininventories. Decisionsoninventoriesinvolvemanydepartments: a. Rawmaterialpoliciesaredecidedbypurchasingandproductiondepartments b. Productiondepartmentplaysanimportantroleinworkinprocessinventory,policyand c. Finishedgoodsinventorypolicyisshapedbyproductionandmarketingdepartments. Butthedecisionsofthesedepartmentshavefinancialimplications.Therefore,asanexecutive entrustedwiththeresponsibilityofmanagingfinanceofthecompany,thefinancialmanagerofthe firmhastoensurethatmonitoringandcontrollinginventoriesofthefirmareexecutedina scientificmannerforattainingthegoalofwealthmaximizationofthefirm.
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LearningObjectives: Afterstudyingthisunit,youshouldbeabletounderstandthefollowing.
RoleofinventoryinworkingCapital: Inventoriesconstituteanimportantcomponentofafirmsworkingcapital.Thefollowingfeatures ofinventoryhighlightthesignificanceofinventoryinworkingcapitalmanagement. 1. Characteristicsofinventoryascurrentassets. Currentassetsarethoseassetswhichareexpectedtoberealizedincashorsoldorconsumed duringthenormaloperatingcycleofthebusiness.Variousformsofinventoryinany manufacturingunitare: a. Rawmaterialstobeconvertedintofinishedgoodsthroughtheprocessofproduction. b. Workinprocessinventoriesaresemifinishedproductsintheprocessofbeingconverted intofinishedgood. c. Finishedgoodsinventoriesarecompletelymanufacturedproductsthatcanbesold immediately. Thefirsttwoareinventoriesconcernedwithproductionandthethirdismeantforsmooth performanceofmarketingfunctionofthefirm. Natureofbusinessinfluencesthelevelsofinventorythatafirmhastomaintaininthesethree kinds.Amanufacturingunitwillhavetomaintainhighlevelsofinventoryinallthethreeforms.A retailfirmwillbemaintainingveryhighleveloffinishedgoodsinventoryonly. Thethreekindsofinventorieslistedabovearedirectinventories.Thereisananotherformof indirectinventories.Theseindirectinventoriesarethoseitemwhicharenecessaryfor manufacturingbutdonotbecomepartofthefinishedgoods.Theyarelubricants,grease,oil, petrol,officematerialmaintenancematerialetc. TheInventoriesareheldforthefollowingreasons. 1. Smoothproduction:toensuresmoothproductionaspertherequirementsofmarketing department,inventoriesareprocuredandsold.
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2. ToachieveCompetitiveedge:Mostofthe retailandindustrialorganizationscarryinventory toensurepromptdeliverytocustomers.Nofirmlikestolosecustomersonaccountofthe itembeingoutofstock. 3. Toreapthebenefitsofbuyinginlargevolume.Sometimesbuyinginlargevolumesmaygive thefirmquantitydiscounts.Thisquantitydiscountsmaybesubstantialthatthefirmwilltake benefitofit. 4. Hedgeagainstuncertainleadtimes:Leadtimeisthetimerequiredtoprocurefreshsupplies ofinventory.Uncertaintyduetosuppliertakingmorethanthenormalleadtimewillaffectthe productionscheduleandtheexecutionoftheordersofcustomersaspertheordersreceived fromcustomers.Toavoidalltheseproblemsarisingfromuncertaintyinprocurementoffresh suppliesofinventories,thefirmsmaintainhigherlevelsofinventoriesforcertainitemsof inventory. 2. Levelofliquidity:Inventoriesaremeantforconsumptionorsale.Bothexcessandshortage ofinventoryaffectofthefirms.Profitability. Thoughinventoriesarecalledcurrentassets,incalculatingabsoluteliquidityofafirminventories areexcludedbecauseitmayhaveslowmovingordormantitemsofinventorywhichcannotbe easilydisposedof.Thereforelevelandcompositionofinventorysignificantlyinfluencethe quantumofworkingcapitalandhenceprofitability ofthefirm. 3. LiquidityLags:Inventorieshavethreetypesoflags. a. Creationlag: Rawmaterialsarepurchasedoncreditandconsumedtoproduce finishedgoods.Thereisalwaysalaginpaymenttosuppliers fromwhomraw materialsareprocured. Thisiscalledspontaneousfinance.Theamountof spontaneousfinancethatafirmiscapableofenjoyinginfluencesthequantumof workingcapitalofafirm. b. Storagelag: Thegoodsmanufacturedorheldforsalecannotbeconvertedinto cashimmediately.Beforedispatchingthegoodstocustomersonsale,thereis alwaysatimelag.Duringthistimelaggoodsarestoredinwarehouse.Many expensesofstoragewillberecurringinnatureandcannotbeavoided.Thelevel ofexpenditurethatafirmincursonthisaccountisinfluencedbytheinventory levelsofthefirm.Thisinfluencestheworkingcapitalmanagementofafirm. c. SaleLag:Firmsselltheirproductsoncredit.Thereissometimelagbetweensale offinishedgoodsandcollectionofdues fromcustomers.Firmswhichare aggressiveincapturingmarketsfortheirproductsmaintainhighlevelsofinventory andallowitscustomersliberalcreditperiod.Thiswillincreaseitsinvestmentin
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receivables.Thisincreaseininvestmentinreceivableswillhaveitseffecton workingcapitalofthefirm.
Purposeofinventory: Thepurposeofholdinginventoryisachievingefficiencythroughcostreductionandincreased salesvolume.Thefollowingarethepurposeofholdinginventories. 1. Sales:Customers placeordersforgoodsonlywhentheyneedit.Butwhencustomers approachthefirmwithordersthefirmsmusthaveadequateinventoryoffinishedgoodsto executeit.Thisispossibleonlywhenfirmsmaintainreadystockoffinishedgoodsin anticipation ofordersfromcustomers.Ifafirmsuffersfromcomplaintsfromcustomersof constantlytheproductbeingoutofstock,customersmaymigratetootherproducers.It willaffectthefirmscustomersbase,customerloyaltyandmarketshare. 2. Toavailquantitydiscounts: Suppliersgivediscountsforbulkpurchases.Such discountsdecreasethecostperunitofinventorypurchased.Suchcostreduction increasefirmsprofits.Firmsmaygoinforordersoflargequantitytoavailthemselvesof thebenefitofquantitydiscounts. 3. ReducingorderingCostsandtime Everytimeafirmplacesanorderitincurscostofprocuringit.Italsoinvolvesaleadtime inprocurement.Insomecasestheuncertaintyinsupplyduetocertainadministrative problemsofthesupplieroftheproductwillaffecttheproductionschedulesofthe organization.Therefore,firmsmaintainhigherlevelsofinventorytoavoidtherisksof lengtheningtheleadtimeinprocurement.Therefore,tosaveontimeandcostsfirmsmay placeordersforlargequantities. 4. Reduceriskofproductionstoppages Manufacturingfirmsrequirealotofrawmaterialsandsparesandtoolsforproductionand maintenanceofmachines.Nonavailabilityofanyvitalitemcanstoptheproduction process.Productionstoppagehasseriousconsequences.Lossofcustomersonaccount ofthefailuretoexecutetheirorderswillaffectthefirmsprofitability.Toavoidsuch situations,firmsmaintaininventoriesashedgeagainstproductionstoppages. Therefore,itcanbeconcludedthatthemotivesforholdinginventoriesare 1. Transactionmotive:formakingavailableinventoriestofacilitatesmooth productionandsales. 2. Precautionarymotive:Forguardingagainsttheriskofunexpectedchangesin demandandsupply.
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3.
Speculativemotive:Totakebenefitoutofthechangesinpricesfirmsincrease ordecreasetheinventorylevels.
13.2 Costsassociatedwithinventoriesare: 1. Materialcosts:Thesearethecostsofpurchasingthegoodsandrelatedcostssuchas transportationandhandlingcostsassociatedwithit. 2. OrderingCost:Theexpensesincurredtoplaceorderswithsuppliersandreplenish theinventoryofrawmaterialarecalledorderingcosts.Theyincludecostsofthe following. a. Requisitioning b. Purchaseordering orsetup c. Transportation d. Receiving,inspectingandreceivingatthewarehouse.Thesecostsincrease inproportiontothenumberofordersplaced.Firmsmaintaininglargeinventory levels,placeafewordersandincurlessorderingcosts. 3. CarryingCosts:costsincurredformaintainingtheinventoryinwarehousearecalled carryingcosts.Theyincludeinterestoncapitallockedupininventory,storage, insurance,taxes,obsolescence,deteriorationspoilage,salariesofwarehousestaff andexpensesonmaintenanceofwarehousebuilding.Thegreatertheinventoryheld thehigherthecarryingcosts. 4. Shortagecostsorstockoutcosts:Thesearethecostsassociatedwitheitheradelay inmeetingthedemandorinabilitytomeetthedemandatallduetoshortageofstock. Thesecostsinclude. a. Lossofprofitonaccountsaleslostcausedbythestockout. b. Lossoffuturesalescustomersmigratetootherdealers. c. Lossofcustomergoodwilland d. Extracostsassociatedwithurgentreplenishmentpurchases. Measurementofshortagecostattributabletothefirmsfailuretomeetcustomersdemandis difficultbecauseitisintangibleinnatureanditaffectstheoperationofthefirmnowandinfuture. SelfAssessmentQuestions1 1.Leadtimeisthetimerequiredto_______________. 2.Bothexcessandshortageofinventoryaffectthefirms____________. 3.Precautionarymotiveofholdinginventoryisforguardingagainsttheriskof _____________________andsupply. 4.Costsincurredformaintainingtheinventory inwarehousearecalled______.
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13.3 InventorymanagementTechniques Therearemanytechniquesofmanagementofinventory.Someofthemare: EconomicOrderQuantity: EOQreferstotheoptimalordersizethatwillresultinthelowestorderingandcarryingcostsfor anitemofinventorybasedonitsexpectedusage. EOQmodelanswersthefollowingkeyquantumofinventorymanagement. a. Whatshouldbethequantityorderedforeachreplenishmentofstock? b. HowmanyordersaretobepacedinayeartoensureeffectiveinventoryManagement? EOQisdefinedastheorderquantitythatminimizesthetotalcostassociatedwithinventory management. Itisbasedonthefollowingassumptions: 1. Constantoruniformdemand.Thedemandorusageiseventhroughouttheperiod. 2. Knowndemandorusage:Demandorusageforagivenperiodisknowni.edeterministic. 3. ConstantUnitprice:Perunitpriceofmaterialdoesnotchangeandisconstantirrespectiveof theordersize. 4. ConstantCarryingCosts Thecostofcarryingisafixedpercentageoftheaveragevalueofinventory. 5. Constantorderingcost Costperorderisconstantwhateverbethesizeoftheorder. 6. Inventoriescanbereplenishedimmediatelyasthestocklevelreachesexactlyequaltozero. Consequentlythereisnoshortageofinventory. 7.
TotalCost x Cost
CarryingCosts
OrderingCosts Q
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EconomicorderQuantity
x Q =
2DK Kc
D=Annualusageordemand
x Q =EconomicorderQuantity
EOQ=
Example:
16x0.15
=4000units
2x30000x20
Kc
10
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Timegapbetweentwoorders=365=4days 87 1. ABCSystem:theinventoryofanindustrialfirmgenerallycomprisesofthousandsofitems withdiverseprices,largeleadtimeandprocurementproblems.Itisnotpossibletoexercise thesamedegreeofcontroloveralltheseitems.Itemsofhighvaluerequiremaximum attentionwhileitemsoflowvaluedonotrequiresamedegreeofcontrol.Thefirmhastobe selectiveinitsapproachtocontrolitsinvestmentinvariousitemsofinventory.Suchan approachisknownasselectiveinventorycontrol.ABCsystembelongstoselectiveinventory control. ABCanalysisclassifiesalltheinventoryitemsinanorganizationintothreecategories. A: B: Itemsareofhighvaluebutsmallinnumber.Aitemsrequirestrictcontrol. Itemsofmoderatevalueandsizewhichrequirereasonableattentionofthe management.. C: Itemsrepresentrelativelysmall valueitemsandrequiresimplecontrol. Sincethismethodconcentratesattentiononthebasisoftherelativeimportanceofvarious itemsofinventoryitisalsoknownascontrolbyimportanceandexception.Astheitems areclassifiedinorderoftheirrelativeimportanceintermsofvalue,itisalsoknownas proportionalvalueAnalysis. AdvantagesofABCanalysis: 2. Itensuresclosercontrolsoncostlyelementsinwhichfirmsgreaterpartofresourcesare invested. 3. Bymaintainingstocksatoptimumlevel itreducestheclericalcostsofinventorycontrol. 4. Facilitatesinventorycontrolandcontroloverusageofmaterials,leadingtoeffectivecost control. Limitations: 1. Aneverendingproblemininventorymanagementisadequatelyhandlingthousandsoflow valueofcitems.ABCanalysisfailstoanswerthisproblem. 2. IfABCanalysisisnotperiodicallyreviewedandupdated,itdefeatsthebasicpurposeofABC approach.
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13.3.1DeterminationofStockLevels Mostoftheindustriesaresubjecttoseasonalfluctuationsandsalesduringdifferentmonthsofthe yearareusuallydifferent.If,however,productionduringeverymonthisgearedtosalesdemand ofthemonth,facilitieshavetoinstalledtocatertofortheproductionrequiredtomeetthe maximumdemand.Duringtheslackseason,alargeportionoftheinstalledfacilitieswillremain idlewithconsequentuneconomicproductioncost.Toremovethisdisadvantage,attempthasto bemadetoobtainastabilizedproductionprogrammethroughouttheyear.Duringtheslack season,therewillbeaccumulationoffinishedproductswhichwillbegraduallyclearedassales progressivelyincrease.Dependinguponvariousfactorsofproduction,storingandcost,anormal capacitywillbedetermined.Tomeetthepressureofsalesduringthepeakseason,however, highercapacitymayhavetobesuedfortemporaryperiods.Similarly,duringtheslackseason,to avoidlossduetoexcessiveaccumulation,capacityusagemayhavetobescaleddown. Accordingly,therewillbeamaximumcapacityandminimumcapacity,onlyconsumptionofraw materialwillaccordinglyvarydependinguponthecapacity usage. Again,thedeliveryperiodorleadtimeforprocuringthematerialsmayfluctuate.Accordingly, therewillbemaximumandminimumdeliveryperiodandtheaverageofthesetwoistakenasthe normaldeliveryperiod. MaximumLevel: Maximumlevelisthatlevelabovewhichstockofinventoryshouldneverrise.Maximumlevelis fixedaftertakingintoaccountthefollowingfactors: 1. Requirementandavailabilityofcapital 2. Availabilityofstoragespaceandcostofstoring. 3. Keepingthequalityofinventory intact 4. Pricefluctuations 5. Riskofobsolescence,and 6. Restrictions,ifany,imposedbythegovernment.
MaximumLevel Where,
Orderinglevel(MRCxMDP)+standardorderingquantity.
MRC=minimumrateofconsumption MDP=minimumleadtime.
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Where, OL=orderinglevel NRC=Normalrateofconsumption NLT=NormalLeadTime. OrderingLevel: Orderinglevelisthatlevelatwhichactionforreplenishmentofinventoryisinitiated. OL=MRCXMLT Where, MRC=Maximumrateofconsumption MLT=Maximumleadtime.
Averagestocklevelindicatestheaverageinvestmentinthatitemofinventory.Itinofquite relevantfromthepointofviewofworkingcapitalmanagement.
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Toarriveatthereorderpointundercertaintythetwokeyrequireddetailsare: 1. Leadtime 2. Averageusage leadtimereferstotheaveragetimerequiredtoreplenishtheinventoryafterplacingorders forinventory Reorderpoint=leadtimexAverageusage Undercertainty,reorderpointreferstothatinventorylevelwhichwillmeettheconsumption needsduringtheleadtime. SafetyStock:Sinceitisdifficulttopredictinadvanceusageandleadtimeaccurately,provision ismadeforhandlingtheuncertaintyinconsumptionduetochangesinusagerateandleadtime. Thefirmmaintainsasafetystocktomanagethestockoutarisingoutofthisuncertainty. Whensafetystockismaintained,(WhenVariationisonlyinusagerate) Reorderpoint=leadtimexAverageusage+Safetystock Safetystock= [(maximumusagerate)(Averageusagerate)]xleadtime. Or Safetystockwhenthevariationinbothleadtimeandusageratearetobeincorporated. Safetystock=(Maximumpossibleusage)(Normalusage) Maximumpossibleusage=MaximumdailyusagexMaximumleadtime Normalusage=AveragedailyusagexAverageleadtime Example:Amanufacturingcompanyhasanexpectedusageof50,000unitsofcertainproduct duringthenextyear.RecostofprocessinganorderisRs20andthecarryingcostperunitper annumisRs0.50.Leadtimeforanorderisfivedaysandthecompanywillkeepareserveoftwo daysusage.Calculate1.EOQ2.Reorderpoint.Assume250daysinayear Solution: 2DK 2x50000x20
EOQ=
=2000units
Kc
0.50
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Reorderpoint(leadtimexAverageusage)+safetystock (5x200)+400=1,400units
13.3.2 Pricingofinventories Therearedifferentwaysofpricinginventoriesusedinproduction.Iftheitemsininventoryare homogenous(identicalexceptforinsignificantdifferences)itisnotnecessarytousespecific identificationmethod.Theconvenientpriceisusingacostflowassumptionreferredtoasaflow assumption. Whenflowassumptionisuseditmeansthatthefirmmakesanassumptionastothesequencein whichunitsarereleasedfromthestorestotheproductiondepartment. Theflowassumptionsselectedbyacompanyneednotcorrespondtotheactualphysical movementofrawmaterials.Whenunitsofrawmaterialareidentical,itdoesnotmatterwhich unitsareissuedfromthestorestotheproductiondepartment. Themethodselectedshouldmatchthecostswiththerevenuetoensurethattheprofitsare uncertaininamannerthatreflectstheconditionsactuallyprevalent. 1. Firstin,firstout(FIFO):Itassumesthattherawmaterials(goods)receivedfirstareusedfirst. Thesamesequenceisfollowedinpricingthematerialrequisitions. 2. LIFO(lastin,firstout):Theconsignmentlastreceivedisfirstusedandifthisisnotsufficient fortherequisitionsreceivedfromproductiondepartmentthentheuseismadefromthe immediatepreviousconsignmentandsoon.Therequisitionsarepricedaccordingly.This methodisconsideredtobesuitableunderinflationaryconditions.Underthismethodthecost ofproductionreflectsthecurrentmarkettrend.Theclosinginventoryofrawmaterialwillbe valuedonaconservativebasisundertheinflationaryconditions. 3. Weightedaverage:Materialissuesarepriced,attheweightedaveragecostofmaterialsin stock.Thismethodconsidersvariousconsignmentsinstockalongwiththeirunitspricesfor pricingthematerialissuesfromstores. 4. othermethodsare: a. Replacementpricemethod:Thismethodpricestheissuesatthevalueatwhichitcanbe procuredfromthemarket. b. Standardpricemethod:underthismethodthematerialsarepricedatstandardprice. Standardpriceisdecidedbasedonmarketconditionsandefficiencyparameters.The differencebetweenthepurchasepriceandthestandardpriceisanalyzedthroughvariance analysis.
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13.4Summary
Inventoriesformpartofcurrentassetsoffirm.Objectivesofinventorymanagementare. a. Maximumcustomersatisfaction b. Optimuminvestmentininventoryand c. Operationoftheplantattheleastcoststructure.Inventoriescouldbegroupedintodirect inventoriesarerawmaterials,workinprocessinventoriesandfinishedgoodsinventory. Indirectinventoriesarethoseitemswhicharenecessaryforproductionprocessbutdonot becomepartofthefinishedgoods.Therearemanyreasonsattributabletoholdingof inventorybythemanagements. TerminalQuestions 1. Examinethereasonsforholdinginventoriesbyafirm. 2. Discussthetechniquesofinventorycontrol. 3. Discusstherelevanceandfactorsthatinfluencethedeterminationofstocklevel. 4. Explainthevariouscostofinventorydecision.
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4. EOQ. AnswerforTerminalQuestions
1. Refertounit13.1
2. Referto13.3 3. Referto13.3.3 4. Referto13.2
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