Professional Documents
Culture Documents
Part-II
Inventory Management
EOQ Problem 1:
Let monthly demand at a retailer is 1000 units.
Inventory Management
Annual demand, D = 1,000 x 12 = 12,000 units
Order cost per lot, Co = Rs 4,000
Unit cost of item, C = Rs500
Inventory holding cost per unit per year (as a
fraction of unit cost) Cc = 0.2 x 500 = Rs 100
Inventory Management
Cycle Inventory = Qopt / 2 = 980/2 = 490
Nos. of orders per year = D / Qopt = 12000 /
980 = 12.24
Annual ordering and inventory holding costs
= (D / Qopt )x Co + (Qopt / 2 ) x Cc
Inventory Management
Now if in the previous example, manager
wants to reduce the lot size to 200, then
what are the annual inventory related costs.
With Q=200
(D / Q )x Co + (Q / 2 ) x Cc = Rs 250,000. This lot size is
undesirable as total costs have increased.
Inventory Management
EOQ Problem 2:
The epaint store stocks paint in its warehouse and
EOQ Problem 2
Cc = $0.75 per gallon
Qopt =
Qopt =
Co = $150
2CoD
Cc
2(150)(10,000)
(0.75)
TCmin =
TCmin =
D = 10,000 gallons
CoD
Q
CcQ
2
(150)(10,000)
2,000 +
(0.75)(2,000)
2
Inventory Management
Reorder Point:
Apart from the ordered quantity, decision maker also
need to specify point of time when to place the order.
This point of time is called Reorder Point.
As the daily demand is d and supplier has a lead
time of L days, the demand faced by retailer during
lead time is L x d units.
Therefore, retailer continuously monitors inventory
and when inventory level reaches L x d (the Reorder
point), retailer places a order of Qopt (i.e. EOQ).
4-8
Inventory Management
Insights from cycle stock inventory model
production and
Also,
larger
inventory
shall
require
larger
space
requirements
E.g. Toyota
production.
4-9
Inventory Management
Insights from cycle stock inventory model
Larger retailers (i.e. higher demand) shall have in general
inventory
turnover
ratio,
ordering
costs
has
to
be
decreased.
For high value items (in comparision to small value
4-11
Co = $150
d
Cc 1 p
D = 10,000 gallons
p = 150 gallons per day
2(150)(10,000)
=
32.2
0.75 1 150
= 2,256.8 gallons
CoD
CcQ
d
TC =
+
1 - p = $1,329
Q
2
2,256.8
Q
Production run =
=
= 15.05 days per order= Length
150
p
of time to receive an order
13-12
Production Quantity
Model
D
Number of production runs =
Q
= Nos. of orders per year
10,000
= 4.43 runs/year
2,256.8
= 2,256.8 1 -
= 1,772 gallons
13-13
Quantity Discounts
Quantity discounts: Price per unit decreases as
Quantity Discounts
Quantity discounts: Price per unit
decreases as order quantity increases
Total Inventory cost TC is now given
as
CD
CQ
o
TC =
Q +
+ PD
where
P = per unit price of the item
D = annual demand
13-15
Quantity Discount
Model
ORDER SIZE
0 - 99
100 199
200+
PRICE
$10 (original cost)
8 (d1)
6 (d2)
TC = ($10 )
TC (d1 = $8 )
TC (d2 = $6 )
Carrying cost
Ordering cost
Q(d1 ) = 100
Qopt
Q(d2 ) = 200
13-16
QUANTITY
PRICE
1 - 49
$1,400
50 - 89
1,100
The annual carrying
cost for the 900
stores for a TV is $190, ordering
90+
4-17
Quantity Discount
QUANTITY
PRICE
1 - 49
50 - 89
90+
$1,400
1,100
900
Qopt =
For Q = 72.5
TC =
For Q = 90
TC =
2CoD
Cc
CoD
Qopt
CoD
Q
Co = $2,500
Cc = $190 per TV
D = 200 TVs per year
2(2500)(200)
= 72.5 TVs
190
CcQopt
+ PD = $233,784
2
CcQ
2
+ PD = $194,105
13-18
Inventory Management
Safety Inventory :
Cycle
Inventory Management
4-20
Inventory
Average
Inventory
Cycle Inventory
Safety Inventory
Time
cycle
inventory
plus
safety
Inventory Management
Tradeoff - Increases safety inventory improves
product
availability
but
it
also
increases
Inventory Management
Level
of Safety
capturing :
inventory
is
decided
by
1. Uncertainty in demand
2. Uncertainty in supply
4-24
Inventory Management
Capturing Uncertainty:
Uncertainty in demand is captured using demand
distribution.
In real life situations, demand can be assumed to
is
measured
using:
Standard
deviation , Coefficient of variation, Range.
Standard
deviation
is
most
widely
used
measure.
4-25
Inventory Management
Coefficient of Variation = Standard deviation / Mean
Standard Deviation alone do not capture uncertainty
Slow moving items typically have higher uncertainty and higher
4-26
Inventory Management
Demand distribution is characterized by mean demand
n days.
Mean or average demand = d=(d1 + d2+ d3+ d4 . dn )/
n
Standard deviation of daily demand = d
= ((d1 - d)^2 + (d2 - d)^2 + .(dn - d)^2) / n
Similarly for supply uncertainty, mean lead time
4-27
Inventory Management
is the standard
of uncertainty in actual
uncertainty is supply.
demand
and/or
4-29
Inventory Management
Value of LTD and Lead Time Demand can be calculated
4-30
Inventory Management
Safety Stock = K x Lead Time Demand
if L
is zero
Inventory Management
LTD = d L
Safety Stock
Probability of
a stockout
Safety stock
Kd L
dL
Demand
13-33
Inventory Management
Inventory Management
There exists a relationship between service level and
13-39
Inventory Control
Systems
Continuous system (fixed-order-quantity)
predetermined level
Inventory is not tracked continuously
Time between orders is not fixed
Order quantity is fixed
Inventory Management
Impact of Supply Chain Redesign on Inventory: Impact
of Aggregation : Centralisation vs Decentralisation
Any supply chain redesign has a significant impact on costs
especially inventory and transportation costs.
With centralization, firm will be able to reduce inventory
related costs but will increase its transportation cost to
maintain same service level.
Supply chain managers need to justify the same with
rigorous cost benefit analysis by taking into account
inventory related costs and transportation costs.
4-41
Impact of Aggregation on
Safety Inventory
Aggregation
and
safety
inventories
in
Centralisation
Di:
i:
, k
ij:
D C Correlation
C
1 i
jk
D
k
k
: Demand
faced
by
Central
location
C
C
2
2 ;
D Di ;
i1
location
var D
i1
DC var DC
ij
i j
Inventory Management
Centralization vs Decentralization
Illustration:
Let us consider the case of a company that currently has 16
regional stock points/warehouses and serves its dealers
from the closest stock point.
The supply chain manager is exploring the option of
centralising its inventory.
Let each region have similar demand distribution with
mean daily demand=d= 100 and standard deviation = 30.
Demand of different regions in independent
Each stock point/ warehouse in both centralisation and
decentralization gets served by plant with lead time of
exactly 15 days.
4-43
Inventory Management
Average transportation cost in decentralization case is
4-44
Inventory Management
Cycle Inventory:
Centralized case
Inventory Management
Safety Inventory:
Demand faced by centralized stock point:
d = d1 +d2 + d3dn
D = d12 + d22 + d32 . dn2
The phenomenon is called Risk Pooling
which suggests that demand uncertainty is reduced
when demand across demand locations is pooled.
It happens because higher demand in one loaction
offsets lower demand in another location.
Lower demand uncertainty leads to lower safety
stock in the centralized case.
4-46
Inventory Management
Safety Stock:
In case of centralisation
D = 302 x 16 = 120
Safety stock
= K D L = 2 x 120 x 15 = 3600
In case of Decentralisation
= K d L = 2 x 30 x 15 = 232
4-47
Inventory Management
Decentralised
stock points
system
16
Centralised
stock point
800
3200
232
928
(232+800) 16
= 16512
928+3200
= 4128
16512 6
= 99072
4128 6
= 24768
Incremental
cost
Transportation
system
300100160.1
=48,000
4-48
Inventory Management
Note:
Safety stock decreases due to risk pooling and
lower demand uncertainty faced by centralised
location.
Cycle stock in centralized case reduces because of
economies of scale.
If in this case, transportation costs say increases by
Impact of Aggregation on
Safety Inventory
The Square-Root Law
Inventory Management
Centralisation vs Decentralisation:
i. Higher the demand uncertainty of the product, higher
transportation
cost,
it is better to centralise.
iv.Higher the nos. regional stock points, higher will be the
Inventory Management
Inventory Management
Managerial Levers to Reduce safety Stock:
1.Reduction in Demand Uncertainty:
Inventory Management
Managing Seasonal Inventory:
A firm that faces seasonal variation in demand
Inventory Management
Illustration:
A toy manufacturer faces demand for toys as given.
Inventory carrying cost per unit per quarter is Rs3.
Each worker can produce 500 units of toys per quarter.
Each temporary worker hired during the peak demand
quarter (Q4) will result in additional cost of Rs 6000.
Manufacturer needs to decide whether to pursue
chase or level option to meet demand.
Relevant costs to be considered are the incremental
Inventory Management
Illustration: Managing Seasonal
Q1StockQ2
Q3
Q4
Demand
8000
8000
8000
12000
Production
9000
9000
9000
9000
Hiring Cost
Inv. C. Cst
3000
6000
9000
Production
8000
8000
8000
12000
Hiring Cost
48000
Inv. C. Cst
Level option
Chase option
Inventory Management
Short lifecycle products:
1.
2.
3.
4.
5.
Inventory Management
Optimum Order size for short life cycle
products
Cu = Cost of understocking
Co = Cost of Overstocking
Optimal service level = (Cu x 100) / (Cu + Co)
Optimal order size = Mean Demand + K x
standard deviation of demand
K = Service factor
Cost of understocking is an opportunity loss by the
firm for each unit of lost sales.
The cost of overstocking is the loss incurred by a
firm for each unit at the end of the selling season.
4-58
Inventory Management
Illustration: Optimum Order for a New Music
CD
CD purchase price = Rs. 200
CD sales price = Rs. 300
CD sales price after first weeks = Rs. 62.
Demand: Average 100 and Standard Deviation 30
Find optimum order quantity.
If manufacturer offers buyback scheme
with
cost of administering return- Rs. 53, what would
be the decision?
Inventory Management
With Cu = 100, Co = 138
Optimum service level = .42 = 42 %
Corresponding K = -0.2
Optimum order size = 100 0.2 x 30 = 94
In case of buyback:
Cu = 100, Co = 53
Optimum service level = .655 = 65.5 %
Corresponding K = 0.4
Optimum order size = 100 + 0.4 x 30 = 112
4-60
Inventory Management
Multiple item, Multiple location Inventory
Management:
1. Managing inventory in actual supply chain involves
Inventory Management
For
Inventory Management
1. ABC Classification:
Items are classified on the basis of sales on value terms.
A = very Important
B = Moderate Important
C = Little Important
ABC analysis is used for a) allocation of management time b)
Improvement Efforts c) Setting up service levels d) Stocking
decisions e.g. A category items at regional distribution
points, C category items at central warehouse, B category
at few regional locations
4-63
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
13-64
ABC Classification
Illustration:
The maintenance department for a small
manufacturing firm has responsibility for
maintaining an inventory of spare parts for the
machinery it services. The parts inventory, unit
cost, annual usage are given in following table.
The department manager wants to classify the
inventory parts according to the ABC system to
determine which stocks of parts should be
closely monitored.
4-65
ABC ClassificationIllustration
PART
UNIT COST ANNUAL USAGE/Demand
1
2
3
4
5
6
7
8
9
10
$ 60
350
30
80
30
20
10
320
510
20
90
40
130
60
100
180
170
50
60
120
13-66
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 % CUMMULATIVE
6.0
5.0
4.0
9.0
6.0
10.0
18.0
13.0
12.0
17.0
A
B
C
6.0
11.0
15.0
24.0
30.0
40.0
58.0
71.0
83.0
100.0
13-67
ABC Classification
CLASS
A
B
C
ITEMS
9, 8, 2
1, 4, 3
6, 5, 10, 7
% OF TOTAL
VALUE
71.0
16.5
12.5
% OF TOTAL
QUANTITY
15.0
25.0
60.0
Example 10.1
13-68
Inventory Management
2. FSN classification
Items are classified as Fast moving , slow
moving and non-moving.
Slow moving items are stored centrally and
fast moving items are stocked de-centrally.
Non-moving items are candidates for disposal.
This type of classification is popular in retail
industry.
4-69
Inventory Management
3. VED Classification:
Items are classified on criticality:
Vital = V, Essential = E , Desirable = D
This type of classification is popular in
maintenance management.
One can fix different service levels for
different items.
4-70
products
Tires for autos are a dependent demand item
Independent
Demand for items used by external
customers
Cars, appliances, computers, and houses are
examples of independent demand inventory
13-71
Inventory Management
Decoupling Inventory:
4-72
Inventory Management
Pipeline Inventory:
It consists of materials actually being worked on (workin-process inventory) or being moved from one location
to another in the chain (on transit inventory).
Pipeline
inventory
of
an
item
between
two
Inventory Management
Illustration :
LT -Shipment by air = 7 days
LT- Shipment by sea = 45 days
Average demand = 100/day
Pipeline Inventory ( Shipment by air) = 700 units
Pipeline Inventory ( Shipment by Sea = 4500
units
Inventory Management
Dead Inventory or Stock:
Dead Stock refers to that part of non-moving
inventory that is unlikely to be of any further use
in supply chain operations or markets.
Dead Stock, essentially includes items that have
become obsolete because of changes in customer
preferences, design, production processes.
Unfortunately, in many firms dead stock is
allowed to accumulate as disposal of dead stock
show up in balance sheets as financial loss.
Rather it is wrongly shown as assets.
Firms should carefully monitor dead stock and find
means to reduce it.
4-75