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Lecture Outline
What Is Inventory?
Stock of items kept to meet future demand
Purpose of inventory management
how many units to order
when to order
Importance of Inventory
Balance the advantages and
disadvantages of small and large
inventories
Pressures for small inventories
Importance of Inventory
Pressures for large inventories
Customer service
Ordering cost
Setup cost
Labor and equipment utilization
Transportation cost
Payments to suppliers
In Short,
Buffer against uncertainty in..
Supply (Raw material inventories)
Production process ( Work in process inventories)
&
Demand (Finished good inventories)
Inventory Management
To have the correct inventory at the right place
at the right time to minimize system costs while
satisfying customer service requirements
Raw material/WIP/Finished goods
Inventory Policy
The strategy, approach, or set of techniques
used to determine how to manage inventory
Type of Inventory
Process
stage
Raw Materials
WIP
Finished Goods
Demand
Type
Independent
Dependent
Purpose
Cycle
Safety
Seasonal
Pipeline
Others
Spares
Consumable
Dependent Demand
(demand for item is dependent
upon the demand for some
other item)
Materials With
Independent Demand
Materials With
Dependent Demand
Demand
Source
Company Customers
Parent Items
Material
Type
Finished Goods
Method of
Estimating
Demand
Planning
Method
Calculated
MRP
Cycle stocks
Due to fixed transportation and handling charges or set up
requirements, it is economical to order or produce large quantities
at a time.
Safety stocks
These are built as a hedge against uncertainties in supply or
demand.
Pipeline stocks
Inventories in-transit.
Inventory Costs
Carrying cost
cost of holding an item in inventory
Ordering cost
cost of replenishing inventory
Shortage cost
temporary or permanent loss of sales when
demand cannot be met
Holding cost = H (% of C)
carrying one unit in inventory for a specified period of time i.e. Rs. H/Unit/Year
Demand in one 1 year, d = average demand per week, So, D = d *52 / years
Inventory Cost
Holding Costs (H)
Obsolescence
Insurance
Extra staffing
Interest
Pilferage
Damage
Warehousing
etc.
Inventory Cost
Holding cost (H)
Cost of Capital
Obsolescence cost
Handling cost
Occupancy cost
Miscellaneous costs
Inventory Cost
Ordering cost (S)
Buyer time
Receiving costs
Transportation costs
Shortage Costs
When occurs,
possibilities..
company
faces
two
So. It depends on
How company handles the problem ?
Shortage Costs
Permanent
Lost profits due to unsatisfied demand
Lost profits of future sales
Temporary (CB)
Backordered, so not necessarily lost
Special clerical & paperwork costs
Extraordinary transportation cost to customer
ABC Analysis
ABC Classification
Class A
5 15 % of units
70 80 % of value
Class B
30 % of units
15 % of value
Class C
50 60 % of units
5 10 % of value
ABC Classification
PART
1
2
3
4
5
6
7
8
9
10
UNIT COST
$ 60
350
30
80
30
20
10
320
510
20
ANNUAL USAGE
90
40
130
60
100
180
170
50
60
120
TOTAL VALUE
ABC Classification
PART
9
8
2
1
4
3
6
5
10
7
TOTAL
VALUE
$30,600
16,000
14,000
5,400
4,800
3,900
3,600
3,000
2,400
1,700
$85,400
% OF TOTAL
VALUE
35.9
18.7
16.4
6.3
5.6
4.6
4.2
3.5
2.8
2.0
% OF TOTAL
QUANTITY
6.0
5.0
4.0
9.0
6.0
10.0
18.0
13.0
12.0
17.0
% CUMMULATIVE
A
B
C
6.0
11.0
15.0
24.0
30.0
40.0
58.0
71.0
83.0
100.0
ABC Classification
CLASS
A
B
C
ITEMS
9, 8, 2
1, 4, 3
6, 5, 10, 7
% OF TOTAL
VALUE
% OF TOTAL
QUANTITY
71.0
16.5
12.5
15.0
25.0
60.0
ABC Problem
Bookers Book Bindery divides SKUs into three classes, according to
their dollar usage.
Calculate the usage values of the following SKUs and determine which is
most likely to be classified as class A.
SKU Number
Description
Boxes
Quantity Used
per Year
Unit Value
($)
500
3.00
Cardboard
(square feet)
18,000
0.02
Cover stock
10,000
0.75
Glue (gallons)
75
40.00
Inside covers
20,000
0.05
Reinforcing tape
(meters)
3,000
0.15
Signatures
150,000
0.45
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Top margin:
Name:
Roll No.:
Group#: (1 or 2)
-------------------------------------------------------------------
Inventory Level
Order quantity, Q
Demand
rate
Average
inventory
Q
2
Reorder point, R
Lead
time
Order Order
placed receipt
Lead
time
Order Order
placed receipt
Time
D - annual demand
Q - order quantity
SD
Q
HQ
2
Total cost =
SD
Q +
HQ
2
H
2
SD
H
0 = Q2 + 2
Qopt =
2SD
H
Proving equality of
costs at optimal point
SD
HQ
Q = 2
2SD
Q = H
2
Qopt =
2SD
H
Total Cost
Slope = 0
HQ
Carrying Cost = 2
Minimum
total cost
SD
Ordering Cost = Q
Optimal order
Qopt
Order Quantity, Q
EOQ Example
H = $0.75 per gallon
Qopt =
2SD
H
Qopt =
2(150)(10,000)
(0.75)
S = $150
D = 10,000 gallons
SD
HQ
TCmin = Q + 2
TCmin =
(150)(10,000) (0.75)(2,000)
+
2,000
2
Q(1-d/p)
Maximum
inventory
level
Q
(1-d/p)
2
Average
inventory
level
0
Order
receipt period
Begin
End
order order
receipt receipt
Time
d = demand rate
TC =
Q
d
1 p
2
SD
HQ
d
+
1
Q
2
p
2SD
Qopt =
d
H 1p
2SD
Qopt =
TC =
H 1-
D = 10,000 gallons
p = 150 gallons per day
2(150)(10,000)
d
p
SD
HQ
d
+
1
Q
2
p
Q
Production run =
p
32.2
0.75 1 150
= 2,256.8 gallons
= $1,329
2,256.8
= 150
10,000
D
=
= 4.43 runs/year
2,256.8
Q
d
Maximum inventory level = Q 1 p
= 2,256.8 1 -
= 1,772 gallons
32.2
150
Quantity Discounts
Price per unit decreases as order
quantity increases
HD
SQ
TC = Q + 2 + PD
where
P = per unit price of the item
D = annual demand
PRICE
$1400
$1100
$900
TC = ($1400)
TC ($1100)
TC ($900)
Carrying cost
Ordering cost
Q1 = 49
Qopt=72.5
Q2= 90
Quantity Discount
QUANTITY
PRICE
1 - 49
50 - 89
90+
$1,400
1,100
900
Qopt =
2SD
H
S = $2,500
H = $190 per TV
D = 200 TVs per year
2(2500)(200)
= 72.5 TVs
190
For Q = 72.5
HQopt
SD
TC = Q
+
+ PD = $233,784
2
opt
For Q = 90
HQ
SD
TC = Q + 2
+ PD = $194,105
Reorder Point
R = dL
where
d = demand rate per period
L = lead time
Reorder Point
Demand = 10,000 gallons/year
Store open 311 days/year
Daily demand = 10,000 / 311 = 32.154
gallons/day
Lead time = L = 10 days
R = dL = (32.154)(10) = 321.54 gallons
Safety Stock
Safety stock
buffer added to on hand inventory during lead time
Stockout
an inventory shortage
Service level
probability that the inventory available during lead
time will meet demand
P(Demand during lead time <= Reorder Point)
Inventory level
Reorder
point, R
LT
LT
Time
Inventory level
Reorder
point, R
Safety Stock
LT
Time
LT
Probability of
a stockout
Safety stock
zd L
dL
Demand
Safety stock = z d L
= (1.65)(5)( 10)
= 326.1 gallons
= 26.1 gallons
d
tb
L
d
zd
tb + L - I
tb + L = safety stock
I = inventory level
Q = d(tb + L) + zd
tb + L - I
= (6)(60 + 5) + (1.65)(1.2)
= 397.96 packages
60 + 5 - 8