6th Set of Slides
6th Set of Slides
Introduction
• Inventory is stock of goods
• Inventoryy comes in many
y shapes
p and sizes such as
1
Types of inventory
Inventory models
Independent Demand
A Dependent Demand
B(4) C(2)
D(2)
( ) E(1)
( ) D(3)
( ) F(2)
( )
2
Uses of inventory
• To meet anticipated and un-anticipated demand/lead time fluctuations
3
Objectives of inventory control
• Provide desired customer service level
– Percentage of orders shipped on schedule
• Provide for cost-efficient operations:
– Buffer stock for smooth production flow
– Maintain a level work force
– Allowing longer production runs & quantity discounts
• Minimum inventory investments:
– Inventory turnover
– Weeks, days, or hours of supply
Example: The XYZ Motor Company has annual cost of goods sold of
$10,000,000. The average inventory value at any point in time is $384,615.
Calculate inventory turnover and weeks/days of supply.
• Inventory Turnover:
annual cost of goods sold $10,000,000
Turnover 26 inventory turns
average inventory value $384,615
• Weeks/Days of Supply:
average inventory on hand in dollars $384,615
Weeks of Supply 2weeks
average weekly usage in dollars $10,000,000/52
$384,615
Days of Supply 10 days
$10,000,00 0/260
Only if it is explicitly
stated that the company
follows a 5‐day week
4
Relevant inventory terminology
Item Cost (Cp or price paid for the item
C)
Inventory system
• When to order?
5
Inventory systems
Continuous Review system (Q ‐ Periodic Review System (P
system) – system)
O d quantity
Order tit Q is
i constant
t t Q is
i variable
i bl
6
EOQ model - Assumptions
Only one product is involved
The order quantity arrives in a single shipment (orders are received all at once)
7
What is the optimal quantity to order?
Inventory position D
Number of periods
will be
Q
The average
inventory for each
period is…
Time
Period over which demand for Q has Q
occurred
2
Total Time
8
Finding the optimal quantity to order…
Purchasing cost = D x C
D
Ordering cost = x S
Q
Q
Inventory cost = x H
2
In order now to find the optimal quantity we need to optimize the total
cost with respect to the decision variable (the variable we control)
Which one is
the decision
variable?
9
• Total annual stocking cost (TSC) = annual carrying cost +
annual ordering cost = (Q/2)H + (D/Q)S
Example:
Assume a car dealer that faces demand for 5,000 cars per year, and that it costs
$15,000 to have the cars shipped to the dealership. Holding cost is estimated at
$500 per car per year. How many times should the dealer order, and what
should be the order size?
2(5,000)(15,000)
Q* 548
500
10
Comments on EOQ model
1. At EOQ, ordering cost will be equal to inventory carrying cost
2 The
2. Th ttotal
t l costt curve is
i relatively
l ti l flflatt around
d th
the EOQ
EOQ.
Usage
rate
EOQ
Time
Receive Receive
order order
11
Another Example - Basic EOQ
EOQ = 2 DS / H
EOQ = 2(5,750,000)(595)/9.00
2(5 750 000)(595)/9 00
12
Example: Basic EOQ
13
Model II: EOQ for Production Lots
2 DS p
EOQ = pd
H
14
Example: EOQ for Production Lots
Highland Electric Co. buys coal from Cedar Creek Coal Co. to
generate electricity. CCCC can supply coal at the rate of
3,500 tons per day for $10.50 per ton. HEC uses the coal at a
rate of 800 tons per day and operates 365 days per year.
p
2 DS
EOQ = pd
H
EOQ = 2(292,000)(5,000)/2.10[3,500/(3,500-800)]
= 42,455.5 tons per order
15
Example: EOQ for Production Lots
16
Model III: EOQ with Quantity Discounts
17
Model III: EOQ with Quantity Discounts
4. Compute the TMC for the feasible EOQ (just found in Step 3)
and its corresponding acquisition cost.
18
Example: EOQ with Quantity Discounts
19
Example: EOQ with Quantity Discounts
Reorder
point
Time
Receive Place Receive Place Receive
order order order order order
Lead time
20
Determining Reorder Points
• DDLT Distributions
Order
Quantity
Q
Inventory
Lead Time
Time
Place Receive
order order
21
If demand is known exactly, place an order when
inventory equals demand during lead time.
Reorder
Point
(ROP)
ROP = LxD
Lead Time
Time
D: demand per period
Place Receive
L: Lead time in periods
order order
Recall example:
Assume a car dealer that faces demand for 5,000 cars per year, and that it costs
$15,000 to have the cars shipped to the dealership. Holding cost is estimated at
$500 per car per year. How many times should the dealer order, and what
should be the order size?
What if the lead time to receive cars is 10 days? (when
should you place your order?)
10 10
R = D = 5000 = 137
365 365
S when
So, h ththe number
b off cars on th
the llott reaches
h 137
137, order
d 548
more cars.
EOQ
computed
in slide 20
22
But demand is rarely predictable.
Inventory
L
Levell
Order
Quantity
ROP = ???
Demand???
Order
Quantity
Lead Time Demand X
ROP
Place Receive
order order
23
If Actual Demand > Expected, we Stock Out
Order
Quantity
Stockout
Point
ntory
Inven
Time
Lead Time
Unfilled demand
Place Receive
order order
Order
Quantity
ROP = Expected Demand
U
Uncertain
t i DDemand
d
Average
Time
24
To reduce stockouts we add safety stock
Inventory
Level
Order Quantity
ROP = Q = EOQ
Safety
Stock + Expected
Expected LT Demand
LT
Demand Safety Stock
Lead Time Time
Place Receive
order order
Safety
Stock
25
Safety stock = (safety factor z)(std deviation in LT demand)
Safety
Stock
26
Average Inventory = (Order Qty)/2 + Safety Stock
Inventory
Level
Order
Quantity
EOQ/2
Average
Inventory
Place Receive
order order
27
Example (continued)…
Back to the car lot… recall that the lead time is 10 days and the
expected yearly demand is 5000. You estimate the standard deviation
of daily demand demand to be d = 6. When should you re-order if you
want to be 95% sure you don’t run out of cars?
Since the expected yearly demand is 5000, the expected demand over
the lead time is 5000(10/365) = 137. The z-value corresponding to a
service level of 0.95 is 1.65. So
28
More on the Basis for Setting the Reorder Point
• In the fixed order quantity system, the ordering process is
triggered when the inventory level drops to a critical point, the
reorder point
• This starts the lead time for the item.
• Lead time is the time to complete all activities associated with
placing, filling and receiving the order.
• During the lead time, customers continue to draw down the
inventory
• It is during this period that the inventory is vulnerable to
stockout (run out of inventory)
• Customer service level is the probability that a stockout will
not occur during the lead time
• Th
The amountt off safety
f t stock
t k needed
d d is
i based
b d on the
th degree
d off
uncertainty in the DDLT and the customer service level desired
29
DDLT Distributions
• Select the DDLT that will provide the desired customer level
as the reorder point
30
Example: ROP for Discrete DDLT Distribution
31
ROP for Discrete DDLT Distribution
32
Setting Reorder Point
for a Continuous DDLT Distribution
• The resulting DDLT distribution is a normal distribution with
the following parameters:
EDDLT = LT(d)
OP = LT(d) + z LT(σ d ) 2
33
Example: ROP - Continuous DDLT Distribution
• EDDLT = 15 gallons
• DDLT = 6 gallons
34
Example: ROP - Continuous DDLT Distribution
• Standard Normal Distribution
Area = .2967
Area = .2033
Area = .5 z
0 .833
35
Rules of Thumb in Setting ROP
36
Behavior of Economic Order Period Systems
37
Determining the EOP
EOP
EOP= = 2S/DH
2S / DC
38
Inventory classification system
• Realistic
R li i to allocate
ll controll efforts
ff according
di to the
h relative
l i
importance of various items in inventory
ABC approach
39
ABC approach
40
Steps 2,3:List in descending order, Calculate
cumulative frequency
41
Other selective inventory control techniques…
Nomenclature Criteria Application
SOS (Seasonal, off‐season) Soya bean, mangoes Should buy in harvest season
to get price advantage and
good quality supply
• VED analysis
• SDE analysis
• FSN analysis
• HML analysis
• GOLF analysis
• SOS analysis
42
VED analysis
SDE analysis
• Based on availability
–SScarce
• Managed by top level management
• Maintain big safety stocks
– Difficult
• Maintain sufficient safety stocks
– Easily available
• Minimum safety stocks
43
FSN analysis
• Based on utilization.
–FFastt moving.
i
– Slow moving.
– Non-moving.
• Non-moving items must be periodically reviewed to prevent
expiry & obsolescence
HML analysis
44
GOLF analysis
SOS analysis
– S = Seasonal items
45