Professional Documents
Culture Documents
1. De f in it io n o f Inve nto ry .
De fin itio n o f Inv e nto ry .
- Thos e stocks o r ite ms us e d to s uppo rt productio n, s uppo rting a ctivitie s , a nd custome r s e rvice .
- De ma nd fo r inve nto ry may be de pe nde nt o r inde pe nde nt.
- Inve nto ry functio ns a re a nticipation, he dge , cycle , fluctua tion, tra ns po rtation, a nd s e rvice pa rts .
- In the the o ry of constra ints .
Inve nto ry is define d a s thos e ite ms purcha s e d fo r re s a le a nd include s finis he d goods ,
ra w ma te ria ls .
Inve nto ry is a lways va lue d a t purcha s e d p rice a nd include s no va lue - a dde d costs , a s
o ppos e d to the tra ditio na l cost a ccounting pra ctice of a dd ing dire ct la bo r a nd a lloca ting
ove rhe a d a s wo rk in proce s s prog re s s tho ugh the p roduction proce s s .
Ty pe s o f Inv e nto ry .
- Raw Mate ria ls (RAW).
RAW re p re s e nts a ny mate ria l inputs us e d in a ma nufa cturing p roce s s .
This include s ma nufa cture d products fro m othe r compa nie s , refe rre d to a s finis he d
goods a t s upplying compa ny.
Ra w mate ria ls fo rm the lowe st leve l of a bill- of- mate ria l structure , a nd typica lly
constitute the lo nge s t po rtio n of c u mulative le a d time .
- Wo rk in P roce s s (W IP).
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S pecia l Lecture
Re ple nis hme nt is typica lly by vis ua l review, direct one- for- one re place me nt, or reo rde r point.
C la s s ific a tio ns o f Inv e nto ry .
- This ca te go rie s re la te to time - fe nce s that cla s s ify inve nto rie s in stock in re la tions hip to the ir
us efulne s s in s uppo rting the inve nto ry strate gy.
- Cla s s ificatio ns .
Exce s s .
S urplus .
Ina ctive .
O bs olete .
Cons ignme nt.
Ve ndo r Ma na ge d.
1. Exce s s Inve nto ry.
This is inve nto ry proc ure d o r ma nufa cture d in exce s s of curre nt ope rationa l ne e d.
The definition of "curre nt ne e d " must be e sta blis he d by po licy fo r e a ch raw mate ria l.
Exce s s inve nto ry may occur by pla n, s uch a s lot s izing rule s o r a nticipatio n builds , o r
by a ccide nt.
Re a s ons .
: Inve nto ry re co rd e rro r.
: O rde r ca nce llation.
: Engine e ring s upe rs e dure s .
2. Surplus Inve nto ry.
S urplus inve nto ry a pplie s to ite ms in de ma nd, but the a va ila ble ba la nce is we ll in
e xce s s of ne e d.
The compa ny co uld procure o r ma nufa cture this q ua ntity late r be ca us e the s upply is
longe r tha n the ite m's le a d time .
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Ina ctive inve nto ry is co ns ide re d a n a s s et fro m a n a ccounting pe rs pe ctive , but the re is
no fo re s e e a ble de ma nd.
It is the dire ct re s ult of s urplus inve nto ry tha t ha s not be e n us e d within 12 - 18 months
a nd will not be us e d in fo re s e e a ble future .
4. Obs ole te Inve nto ry.
O bs olete inve nto ry will neve r be us e d o r s o ld at full va lue be ca us e the products a re
no longe r p roduce d o r s uppo rte d .
Dis pos ing of the inve nto ry re duce s a compa ny's profit.
5. Cons ignme nt Inve nto ry.
Cons ignme nt inve nto ry occurs whe n the s up plie r p hys ica lly give s the custo me r the
inve nto ry fo r us e a nd the s upplie r reta ins the title of the product until us e d.
The s upplie r pe riodica lly inve nto rie s the co ns igne d product a nd, a s a re s ult, bills the
c usto me r a nd re ple nis he s the cons igne d inve nto ry.
6. Ve ndo r Ma na ge d.
Ve ndo r ma na ge d inve nto ry diffe rs fro m co ns ignme nt in s eve ra l re s pe cts .
The vis ibility of the custo me r's fo re ca sts , s uch a s p romotio ns a nd productio n ra te s , is
s ha re d with the s upplie r.
Vis ibility ca n be a chieve d with va rio us te c hnologica l a dva nta ge s s uc h a s point- of- s a le
info rma tion o r EDI.
2 . O rde r Re v ie w Me tho do lo g ie s .
Ty pe s o f O rde r Re v ie w Me tho do lo g ie s .
- Mate ria l Re q uire me nts Pla nning (MRP).
- Time - Pha s e d O rde r Po int.
- Re o rde r Po int.
- Pe riodic Review.
- Vis ua l Revie w.
- Ka nba n.
O rde r Re v ie w
Me tho d
Ind e pe nde nt
De m a nd
MR P
Re o rde r P o int
Pe rio d ic Re v ie w
V is ua l Re v ie w
Ka n ba n
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De pe nde nt
De m a nd
MRO
S pecia l Lecture
W ha t T he y A ns w e r.
- What is the ne t de ma nd a fte r a ccounting fo r ava ila ble inve nto ry a nd s che dule d re ce ipts ?
- What is the a va ila ble ba la nce afte r a cco unting fo r s afety stock, a lloca tio ns , a nd yie ld a nd
s c ra p a llowa nce s ?
- What qua ntity will ne e d to be o rde re d afte r a cco unting fo r constra ints a nd mod ifie rs ?
- Whe n will o rde rs ne e d to be re le a s e d to p rovide s ufficie nt time fo r proc ure me nt a nd
ma nufa cturing ?
- Whe n will o rde rs ne e d to be re ce ive d to s uppo rt re quire d date s ?
SS = Sa fe ty Stock.
- The re o rde r point te chnique a s s ume s tha t a re ple nis hme nt o rde r ca n be re le a s e d a nd
re ce ive d befo re a stock- o ut occu rs .
- Be ca us e this te chnique is typica lly us e d fo r inde pe nde nt de ma nd ite ms , a s afety stock is
commo nly ma inta ine d.
- An a s s umption of ste a dy de ma nd is a ls o re quire d, whe re the pa st is a n a de qua te ind icato r of
the future .
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: 600
: 80
: 0
: 2
: 4
Fixe d.
Fixe d.
PART X
Wee ks .
S a le Fo re c a s t.
Inte rpla nt Orde rs .
S pe c ia l Eng ine e ring Ne e ds .
Cha rity Do natio ns .
S pe c ia l Pro motio n.
1
100
2
100
50
3
120
4
100
140
Pe rio ds .
5
6
100
100
: 600
: 80
: 0
: 2
: 4
8
100
10
9
125
20
30
30
80
S afe ty S to c k Inc re a s e .
A ntic ipatio n build up .
De pe nde nt de ma nd .
Gro s s Re quire me nts .
7
100
40
170
30
190
10
130
20
280
3
130
4
280
5
20
205
5
10
125
0
125
Pe rio ds .
5
6
180
160
7
205
8
125
9
125
Pe rio ds .
5
6
180
160
7
205
8
125
9
125
255
130
605
75
600
50
180
40
160
Tec hnique
Fixed.
Fixed.
Wee ks .
1
170
2
190
600
: 600
: 80
: 0
: 2
: 4
Tec hnique
Fixed.
Fixed.
Wee ks .
1
170
200
2
190
600
610
3
130
4
280
480
200
600
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620
60
600
460
600
S pecia l Lecture
Pe rio d ic Re v ie w .
- Known a s a fixe d- inte rva l o rde r syste m, o r fixe d re o rde r cyc le inve nto ry mode l.
- This is a fo rm of inde pe nde nt de ma nd ma na ge me nt mode l in which a n o rde r is pla ce d eve ry
n time units .
- The o rde r qua ntity is va ria ble a nd e s s e ntia lly re pla ce s the ite ms cons ume d du ring the cu rre nt
time pe riod.
- The o rde rs qua ntity mode l be come s mo re co mplicate d whe ne ve r the re ple nis hme nt le a d time
exceeds the review inte rva l, be ca use outsta nding o rde rs the n have to fa cto red into the equation.
- M - x mode l.
M = DD ( L + R ) + S S
Q= M - x - O
whe re
V is ua l Re v ie w .
- The inve nto ry re o rde ring is ba s e d on a ctua lly loo king a t the a mount of inve nto ry on ha nd.
- This methodology is us ua lly us e d fo r low- va lue ite ms .
- A commo n te chnique is to e sta blis h minimum a nd maximum leve ls .
Ka nba n .
- Ka nba n is a s igna l fo r re ple nis hme nt.
- The qua ntity fo r re ple nis hme nt is dete rmine d fro m the rate - ba s e d MRP a s a fixe d- o rde r
q ua ntity, o rde r po int method .
- In a ma nufa cturing e nviro nme nt the upstre a m sta tion doe s not sta rt producing pa rts until it
re ce ive s a s igna l s uch a s a n e mpty bin, o r e mpty floo r s pa ce de s igne d a s a ka nba n.
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S pecia l Lecture
3 . Fa c to rs in Lo t- S iz ing De c is io ns .
O rde r Q ua ntity Co ns t ra ints a nd Mo d ifie rs .
- O rde r qua ntity co nstra ints p rovide uppe r a nd lowe r ma c roa djustme nt limits to the ca lcula te d
q ua ntity.
- They co nstra in the fina l qua ntity betwe e n inclus ive maximum a nd minimum limits .
- Uppe r a nd lowe r limits .
Uppe r limits : They re strict the day's s upply o r do lla rs fo r a ny o rde r.
Lowe r limits : They pre ve nt numbe ro us o rde rs fo r inexpe ns ive pa rts from be ing pla ce d.
- O rde r qua ntity modifie rs p rovide a mic roa djustme nt me cha nis m fo r fine - tuning ca lculate d
q ua ntitie s . This ca n be us e d to a djust the qua ntity to s upplie r o r co mpa ny- s pe cifie d o rde r
multiple s , o r to ta ke a dva nta ge of price bre a ks .
- Sc ra p a nd yie ld fa cto rs a re mod ifie rs .
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4 . Lo t S iz e Te c hn iq ue s .
Ec o no m ic O rde r Q ua ntity (EOQ ).
- The EOQ co nce pt is prima rily us eful a s a te c hnique fo r dete rmining the re latio ns hip betwe e n
ca rrying a nd o rde ring costs .
- The EOQ fo rmula .
2A S
Ci
EOQ =
whe re
A = Annua l Us a ge .
S = Cost pe r O rde r.
C = Cost of Ite m.
CC =
O rde r cost.
OC =
A
S
Q
Q
Ci +
2
A
S
Q
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S pecia l Lecture
Fix e d- O rd e r Q ua ntity .
- Us e of a fixe d- o rde r qua ntity is us ua lly dicta te d by s ome co ndition re la te d to s hipping,
ha ndling, o r line re ple nis hme nt.
- Re ga rdle s s of de ma nd va ria bility, s upplie rs re ce ive cons iste nt o rde rs with co ns iste nt o rde r
q ua ntitie s , but a va ria ble fre que ncy.
- It may be dete rmine d ve ry info rma lly, s uch a s a s e at- of- the - pa nts e stimate , o r it might be
ba s e d on s o me fo rm of ca lcula tio n, s uch a s EOQ.
- The fixe d o rde r qua ntity is s hown in :
Orde r Qua ntity
Safety Stock
Allocate d Qty
Lea d- Time
: 600
: 80
: 0
: 2
Tec hnique
Fixed.
Fixed.
Pe rio ds .
Wee ks .
130
160
120
260
130
120
185
115
125
240
80
460
120
500
500
200
570
10
500
450
265
150
Gross Requirement.
Scheduled Receipts .
Projected Available.
370
Net Requirements.
Planned Order Receipts.
Planned Order Release.
500
85
500
500
Safety Stock = 80
Orde r Qua ntity = POQ
Lead Time = 2
Forecast De ma nd
Scheduled Rece ipts
Projected Ava ila ble
Y
Pla nned Rece ipts
Pla nned Orde r Re leases
Pe rio d s
370
1
130
2
160
3
120
4
260
5
130
6
120
7
185
8
115
240
80
590
630
330
200
80
?
?
630
.* A = 152.5 52 = 7930
.*
E OQ =
* POQ =
2A S
=
C i
27930 10
= 650
1. 500 . 25
EOQ
Ave ra ge Pe riod Usage
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650
152.5
= 4.26 = 4
= 152.5
S pecia l Lecture
Lo t- fo r- Lo t.
- One definition of lot fo r lot is the s um of re quire me nts fo r a pe riod. With MRP re pla nning
nightly, pe riods ca n be a s s ho rt a s one day.
- Co mpa nie s that must o rde r a nd s e g re gate inve nto ry s e pa ra te ly fo r e a c h c usto me r o rde r o r
contra ct ta ke the lot- fo r- lot te chnique furthe r.
- To a ccount fo r the costs of e a ch o rde r, a nd to e liminate o r minimize a ny re s idua ls , ite ms a re
o bta ine d o nly fo r e a ch o rde r.
- No e xplos io n proce s s is re quire d.
- Eve n though, the re a re a dva nta ge s of us ing MRP fo r this o rde ring proce s s .
A common co mpute r syste m is us e d fo r a ll pla nning a nd o rde ring.
The s a me ite m may be s ubje ct to lot- fo r- lot o rde ring fo r ce rta in type s of o rde rs , a nd
re gula r pe riod o r othe r type of o rde ring te chnique fo r othe r o rde rs .
Re s idua ls may exist due to a minimum purc ha s e on a nothe r o rde r, a n o rde r
ca nce llation which le ft inve nto ry in stock, a nd s o o n. The s e re s idua ls will be a pplie d
a utomatica lly by MRP prio r to trigge ring a new o rde r.
Safety Stock = 80
Pe rio ds
Forecast De ma nd
130
160
120
260
130
120
185
115
130
160
80
80
80
120
260
80
80
80
80
80
120
260
130
120
185 115
130
120
185
115
Ta b le 6 . Lo t- fo r- Lo t
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S pecia l Lecture
1. Which of the fo llowing a re cha ra cte rist ics of the time - pha s e d o rde r point (TPO P) me thod ?
. Accommoda te lumpy de ma nd patte rns .
. Us e s a re o rde r po int .
. S hows the timing of pla nne d re ple nis hme nt o rde rs .
A. .
B. ,
C. ,
D. , , .
2. If ca rrying costs we re a djuste d fo r a ll ite ms , with a ll othe r pa ra mete rs re ma ining the s a me , e cono mic
o rde r qua ntitie s would te nd do which of the following ?
A. De c re a s e s lightly fo r o ne o rde ring cycle o nly.
B. Inc re a s e fo r eve ry o rde ring cycle until the ca rrying cost is revis e d downwa rd a ga in.
C. De c re a s e fo r e ve ry o rde ring cycle until the ca rrying cost is revis e d downwa rd a ga in.
D. Not be a ffe cte d at a ll.
3. Which of the fo llowing is a va lid re a s on to o rde r a qua ntity othe r tha n tha t s ugge ste d by the EOQ
fo rmula , give n tha t a ll othe r co nditions fo r us e of the fo rmula a re met ?
. Ina de quate s e lf s a pce .
. Ite m s ubje ct to s po ila ge .
. Cost of the ite m.
A.
B. ,
C. ,
D. , ,
D. A re ce ive d o rde r.
5. The compa ny ha d ma de a majo r e ngine e ring de s ign cha nge to the ir most po pula r prod uct line . This
ha s re s ulte d in the tota l re pla ce me nt a nd pha s e d- out of a numbe r of pu rcha s e d ite m. The re is no
futu re de ma nd fo r a ny of the s e ite ms . Which of the fo llowing a ctions a re a pp ropriate in o rde r to e ns u re
that the pla nne r doe s not re ce ive a ction me s s a ge s from MRP fo r the s e ite ms ?
A. Cha nge the low leve l code to ze ro .
B. Cha nge the pla nne r ID to a non- existe nt pla nne r.
C. No a ctio n is re quire d by the pla nne r.
D. Add a la rge qua ntity to a de s igne d "s u rplus " loca tion s o no o rde r a ction is eve r re quire d.
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S pecia l Lecture
6. The buye r ha s notice d that ce rta in ite ms a t bill of mate ria l leve l 1- 3 a re o rde re d individ ua lly fo r e a ch
custome r o rde r, but tha t multiple price bre a k a re ava ila ble if the o rde rs a re combine d. Which o ne of
the fo llowing s ugge stions s ho uld be ma de to ma na ge me nt fo r co ns ide ratio ns ?
A. Cha nge the bill of mate ria l leve l fo r the se ite ms to leve ls 4- 6 a nd continue to va lue by a ctua l cost.
B. Us e lot- fo r- lot o rde ring a nd va lue the ite ms a t sta nda rd cost, ba s e d on the most favo ra ble p rice
bre a k.
C. Us e multi- line ite m o rde rs to inte rna lly tra c k ite m qua ntity to custo me r o rde r numbe r, a nd va lue
e a ch ite m by a ctua l coat ba s e d o n tota l o rde r cost.
D. Ide ntify the custome r o rde r numbe r o n the purcha s e o rde r to the s upplie r a s "combine d " a nd
have the s upplie r cha rge a ctua l cost ba s e d o n the o rde r qua ntity.
7. A s upplie r ha s e sta blis he d a minimum qua ntity of 50 units of a pa rticula r ite m a nd a rounding qua ntity
of 10. The Fulbright Compa ny o nly ne e ds 10 units fo r a custom e ngine e ring prod uct. Whic h of the
following a ctio ns s hould be ta ke n ?
A. O rde r the rounding qua ntity of 10.
8. The compa ny ha s a prima ry a nd ba ckup s upplie r fo r a pa rticula r ite m. The p rima ry s upplie r ha s no
rounding qua ntity but the ba ckup s upplie r us e s a proce s s tha t produce s ba tc he s of 10. The re quire
o rde rs in multiple s of 10. Whic h of the following a ctio ns s hould the co mpa ny ta ke ?
A. Igno re the ro unding qua ntity fo r both s upplie rs a nd o nly o rde r from the p rima ry.
B. Esta blis h s e pa rate round ing qua ntitie s fo r both s upplie rs .
C. Esta blis h a sta nda rd rounding q ua ntity of 10 to s implify o rde ring re ga rdle s s of the s upplie r.
D. O rde r what is re quire d re ga rdle s s of s upplie r a nd a cce pt a ny exce s s from the ba ckup s upplie r.
9. The compa ny us e s a ca rrying cost va lue of 0.25. which of the fo llowing is the most effe ctive wa y fo r
a pla nne r to re duce a ctua l ca rrying costs ?
A. Re duce the ca rrying cost us e d in o rde r qua ntity ca lc ulatio ns to ze ro.
B. Us e a n o rde r qua ntity te chnique that is not ba s e d o n ca rrying cost.
C. Bypa s s ce ntra l sto re s a nd stock re ce ive d mate ria l ne a r the po int of us e .
D. Esta blis h a days s upply co nstra ints to limit la rge o rde r qua ntitie s .
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S pecia l Lecture
10. The co mpa ny ha s just ne gotiate d to ha ve a ll of the e le ctro nic compo ne nts purcha s e d fro m a loca l
distributo r cha nge d to co ns ignme nt. Which of the fo llowing a ctio ns ne e d to be ta ke n p rio r to the next
re ce ipt fo r the existing inve nto ry ?
A. Co nve rt the ba la nce s to co ns ignme nt to sta nda rdize o n the inve nto ry cla s s ification.
B. Is s ue the ba la nce s to wo rk in proce s s to ze ro out raw mate ria l inve nto ry.
C. Re co rd the ba la nce s a s co mpa ny- owne d inve nto ry s o costs ca n be s e g re gate d.
D. Re d uce the unit costs to ze ro to e liminate payme nts to the s upplie r upo n is s ue .
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