Professional Documents
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Management
Fundamentals of Inventory
Management
From EOQ to ROP G. Ioannou, Ph.D.
Associate Professor
Agenda
Inventory Concepts
Economic Order Quantity (EOQ)
Hybrid Systems
2
Definition - Types
Inventory is created when the receipt of materials, parts
or finished goods exceeds their disbursement.
5
Pressures for Low Inventories
Taxes, Insurance and Shrinkage
More taxes are paid if end-of-year inventories are high.
Insurance on assets are increased when there is more to insure.
Shrinkage takes three forms:
6
Pressures for High Inventories
Customer Service
Creating inventory can speed delivery and improve on-time
delivery.
Inventory reduces the potential for stock-outs and back-orders.
A Stockout occurs when an item that is typically stocked is not
available to satisfy a demand the moment it occurs, resulting in
loss of sale.
A backorder is a customer order that can not be filled when
promised or demanded but is filled later. Customers may be
willing to wait for a backorder but next time may take their
business elsewhere. Sometimes customers are given discounts
for the inconvenience of waiting.
7
Pressures for High Inventories
Ordering Cost
Each time a firm places a new order, it incurs an ordering cost,
or the cost of preparing a purchase order for a supplier or a
production order for the shop.
For the same item, the ordering cost is the same, regardless of
the order size.
The purchasing agent needs to take the time to decide how
much to order, select a supplier and negotiate terms. Time is
also spent on paperwork, follow-up and receiving. In the case of
a production order for a manufactured item, a blueprint and
routing instructions must often accompany the shop order.
8
Pressures for High Inventories
Setup Cost
The cost involved in changing over a machine to produce a
different component or item is the setup cost. It includes labour
and time to make the changeover, cleaning and new tools or
fixtures.
Scrap or rework costs can be substantially higher at the start of
the run.
Setup cost is also independent of order size.
9
Pressures for High Inventories
Labor and Equipment Utilization
By creating more inventory, management can increase workforce
productivity and facility utilization in three ways.
1. Placing larger, less frequent production orders reduces the number
of unproductive setups, which add no value to a product or service.
2. Holding inventory reduces the chance of costly rescheduling of
production orders because the components needed to make the
product are not in inventory.
3. Building inventories improves resource utilization by stabilizing the
output rate for industries when demand is cyclical or seasonal.
The firm uses inventory built during slack periods to handle extra
demand in peak seasons and minimizes the need for extra shifts,
hiring, lay offs, overtime and additional equipment.
10
Pressures for High Inventories
Transportation Cost
Transportation costs can be reduced by increasing inventory levels.
Having inventory on hand allows more carload shipments and minimizes
the need to expedite shipments by more expensive modes of
transportation.
Combining orders of different items from same supplier may lead lead to
rate discounts, thereby decreasing the costs of transportation and raw
materials.
Payments to suppliers
A firm often can reduce total payments to suppliers if it can tolerate higher
inventory levels, if for example it learns that a key supplier is about to
increase prices.
A firm can also take advantage of quantity discounts, whereby the price per
unit drops when the order is sufficiently large.
11
Economic Order Quantity
(EOQ)
Managers face conflicting pressures to keep inventories low enough
to avoid excess inventory holding costs but high enough to reduce
the frequency of orders and setups.
A good starting point for balancing these conflicting pressures and
determining the best cycle-inventory level for an item is finding the
Economic Order Quantity (EOQ).
EOQ is defined as the lot size that minimizes total annual inventory
holding and ordering costs.
12
EOQ Assumptions
When the following assumptions hold, the optimal EOQ can be
calculated analytically:
The model can only be used for "independent" demand and instantaneous
production.
The demand rate is constant and known beforehand.
There are no constraints in terms of lot size.
The only relevant costs are the inventory holding cost and fixed cost per lot
for ordering or setup.
There is no uncertainty in lead-time or supply (immediate).
In reality, very few situations are so simple and well behaved.
Still, EOQ is a reasonable first approximation of average lot sizes.
13
Calculating EOQ
14
Calculating EOQ
When the EOQ assumptions are
satisfied, cycle inventory behaves
as shown. Inventory depletion
Demand rate
On-hand Inventory
A cycle begins with Q units held in
Q
inventory, which happens when a
new order is received. Average
Q/2 cycle
During the cycle, on-hand inventory
inventory
is used at a constant rate.
Since demand is known with time
certainty and the lead time is a Receive Receive
Order Order
constant, a new lot can be ordered
so that inventory falls to 0 precisely 1 cycle
when the new lot is received.
15
Calculating EOQ
Because inventory varies
Annual Cost, $
uniformly between Q and 0, the
average cycle inventory equals
half the lot size, Q. Holding Cost
Q
AHC = H
2
16
Calculating EOQ
Annual Cost, $
per year equals annual demand D
divided by Q. Ordering Cost
The total ordering or setup cost
decreases non-linearly as Q
increases, because fewer orders
are placed.
Lot Size (Q)
Annual ordering cost = (Number of orders / year) x
(Ordering or Setup cost)
D
AOC = S
Q 17
Calculating EOQ
Where: Q D
C = H + S
C = total cost per year 2 Q
Q = lot size in units
H = cost of holding one unit in
inventory for a year, often Annual
calculated as a proportion of Cost
the items value.
D = annual demand in units per year
S = cost of ordering or setting up one Lot size (Q)
lot, in dollars per lot.
18
Calculating EOQ
Q D dC
C = H + S =0
2 Q dQ
Q D
d( H + S) SD H
2 Q 2 + =0
=0 Q 2
dQ
2 DS SD H
EOQ = 2
d ( 2 + )
H d TC Q 2 2SD
2
= = >0
dQ Q H 19
EOQ Reality
Everybody uses it
Why?
It is simple
It is robust (100% error in demand value, only 25%
error in total cost!!!)
It is embedded in all ERP and ex-MRP systems
Holding and set-up costs are fairly insensitive to lot
size
20
EOQ Example
The Heat International Company produces air-conditioners.
The air conditioning units it requires to this purpose are handled as
independent demand.
The production can be assumed stable, as the company implements a Make-
To-Stock policy (production continues normally during winter months).
The demand rate for such air-conditioning units is 500 units per week.
The air-conditioning units supplier charges 0.3 per unit, while the cost of
placing a purchase order is 10.
The annual cost of holding an air-conditioning unit in inventory is 25% of its
value.
If the company orders 5,000 units when its inventory is exhausted, what is the
total cost?
How many air-conditioning units and how often should the company order to
minimize its total cost?
21
EOQ Example
The total annual demand for air-conditioning units is:
D= (500 units / week) x (52 weeks / year) = 26,000 units /year
The annual inventory holding cost for one air-conditioning unit is:
= 0,25 (0.3 / unit) = 0.075
The total cost for ordering 5,000 units, thus, derives:
Q D 5000 26000
C= H + S = 0.075 + 10 = 239.5
2 Q 2 5000
The Economic Order Quantity becomes:
2 DS 2 26000 10
EOQ = = 2633 units
H 0,075
22
EOQ Example
The annual cost for ordering EOQ (2633 units) becomes:
Q D 2633 26000
C = H + S = 0.075 + 10 = 197.48
2 Q 2 2633
EOQ 2633
TBOEOQ = (52weeks / year ) = 52 5,26weeks
D 26000
23
Quantity Discounts Model
Discounts offerings with quantity
constitute motives for ordering higher
quantities and, hence, holding larger
inventories. EOQ 4
The price does not remain constant, EOQ 3.5
EOQ 3
as in the EOQ model, but varies along C for =4
with the ordering quantity. C for = 3.5
Total Cost
Therefore, it becomes crucial to find C for = 3
the trade-off between price discount
and cost increase due to keeping PD for
=$4 PD
for
larger inventory. =$3.5 PD
for
The total annual cost needs to =$3
incorporate except for the inventory 100 200 300 Q
holding cost and ordering (or setup)
cost the purchase cost of the
materials studied. Q D
C = H + S + P D
The total cost becomes: 2 Q 24
Quantity Discounts Model
Calculate EOQ, starting from the lowest price to the next higher price.
Check for feasibility (EOQ within the volume range from the respective
price).
If the first feasible EOQ is found for the lowest price, it is optimal.
Otherwise, calculate total cost for the first feasible EOQ and the larger
price break quantity at each lower price level.
25
Quantity Discounts - Example
The retailer of Heat International is negotiating the air-conditioning
units respective purchase cost along with the quantity ordered.
Heat International offers the discounts summarized in the table
provided below:
Quantity Price /Unit
0 - 299 60
300-499 58,8
500- 57
26
Quantity Discounts - Example
For the lowest price:
2 DS 2 6500 50
EOQ57 = = = 213.57 < 500
H 0.25 57
For the next price:
2 DS 2 6500 50
EOQ58.8 = = = 210.28 < 300
H 0.25 58.8
300 6500
C300 = 0.25 58.8 + 50 + 58.8 6500 = 385,488.3
2 300
The total cost when ordering 500 units:
500 6500
C500 = 0.25 57 + 50 + 57 6500 = 374,712.5
2 500
Since 374,712.5 is the minimum total annual cost, the optimum ordering
quantity is 500 units. 28
Inventory Control Systems
An Inventory Control System answers to the questions:
How much should we order?
When should we order?
In selecting an inventory control system for a particular application, the
nature of the demands imposed on the inventory items is crucial.
An important distinction between types of inventory is whether an item is
subject to dependent or independent demand.
Independent demand is influence by external market conditions and is not
related to the inventory decisions for any other item held in stock.
Dependent demand is required as components or inputs to a product or
service.
Inventory control systems for independent demand inventory is the area we
focus in the following slides.
29
Continuous Review System
(Q)
A continuous review (Q) system or reorder point
(ROP) system or fixed order-quantity system tracks the
remaining inventory of an item each time a withdrawal is
made to determine whether it is time to reorder.
In practice, these reviews are done frequently (e.g. daily)
and often continuously (after each withdrawal).
At each review a decision is made about an items
inventory position.
If it is considered to be too low, the system triggers a new
order.
30
Continuous Review System
(Q) definitions
On-hand inventory OH = inventory count
Schedule receipts SR = supplier orders expected
Backorders BO = customer orders not yet filled
The Inventory Position (IP) measures the items ability
to satisfy future demand.
It includes Scheduled Receipts (SR) plus On-Hand
inventory (OH) minus backorders (BO).
IP=OH+SR-BO
31
Continuous Review System
(Q)
When the inventory position reaches a predetermined
minimum level, called the Reorder point (R), a fixed
quantity Q of the item is ordered.
Reorder point R = minimum allowed IP =
Average demand during supplier lead time
In a continuous review system, although the order quantity
Q is fixed, the time between orders can vary (it can be
based on the EOQ, a price break quantity, a container size,
or some other quantity selected by management).
Reorder point is a predetermined quantity of inventory.
It needs to be sufficient to cover the demand during the lead
time (the time interval between an order placement and an
order delivery).
32
Continuous Review System
(Q) The Case of Deterministic Demand
The downward-sloping line
represents the on-hand inventory,
which is being the depleted at a
order
constant rate. delivery
When it reaches reorder point R
inventory
(the horizontal line), a new order for
Q units is placed.
The on-hand inventory continues to
drop throughout lead time L until the
order is received. R
order
At that time, which marks the end of
time
the lead time, on-hand inventory L L L
jumps by Q units. TBO TBO TBO
A new order arrives just when
inventory drops to 0.
The time between orders (TBO) is
the same for each cycle.
33
Continuous Review System
(Q) The Case of Deterministic Demand
The inventory position IP corresponds to the on-hand inventory, except
during the lead time.
Just after a new order is placed, at the start of the lead time, IP increases
by Q, as shown by the dashed line.
The IP exceeds OH by this same margin (Q) throughout the lead time.
A possible exception is the situation when more than one scheduled
receipts is open at the same time, because of long lead times.
At the end of the lead time, when the scheduled receipts convert to on-
hand inventory, IP=OH once again.
The key point here is to compare IP, not OH, with R in deciding whether to
re-order or not.
34
Continuous Review System
(Q) The Case of Stochastic Demand
In reality, demand and lead times are not always predictable.
This situation gives rise to the need for safety stocks.
In this case, reorder point equals the average demand during lead time plus
the safety stock.
The variability in lead times is assumed
order
delivery negligible.
inventory
37
Continuous Review System
(Q) The Case of Stochastic Demand
service
level
average demand =85% probability
during of not satisfying
lead time demand=
100-85=15%
R
zL
Safety stock is computed by multiplying the number of standard
deviations from the mean needed to implement the cycle-service level z
by the standard deviation of demand during lead time probability
distribution L:
Safety stock = zxL
The higher the value of z, the higher the safety stock and the cycle-
service level should be.
If z=0, there is no safety stock and stockouts will occur during 50% of the
order cycles. 38
Q system Example (1)
Heat International retailer has observed that the demand for air-
conditioning units is not exactly deterministic, but presents a level of
uncertainty.
Following a relevant study, it has been found that the demand for air-
conditioning units during lead time has an average of 100 units and a
variance of 12.
How much units should Heat International keep in safety stock to
ensure that the service level is 99%?
What should the reorder point be?
39
Q system Example (1)
1. Calculate z
z is the number of standard deviations to the right of average demand during
lead time that places 99% of the area under the curve to the left of that point
(0.9900 in the table of Normal Distribution).
The closest number in the table is 0.9901, which gives value of 2.33.
2. The safety stock becomes:
Safety stock = zxL = 2.33x12=27.96 or 28 units.
3. The reorder point is calculated as following:
Reorder point = Average demand during lead time + Safety stock
R = 100+28 = 128 units
40
Continuous Review System
(Q) The Case of Stochastic Demand
In case average demand during the lead time and the standard deviation of
demand during the lead time are not directly available:
If
The average demand d and the standard deviation of demand t over some
time interval t not equal to the lead time L are known
The probability distributions of demand for each time interval t are identical and
independent of each other.
The lead time L is expressed in terms of the time interval t
Average demand during the lead time is the sum of the averages for each of
the L identical and independent distributions of demand, or d+d++d=dL
The variance of the demand distribution for the lead time is the sum of the
variances of the L identical and independent distributions of demand, or t2+
t2+...+ t2 = t2L
The standard deviation of the demand distribution for the lead time is the
square root of the sum of their variances, or L = t2 L = t L
41
Q system Example (2)
Heat International retailer has observed that the demand for
air-conditioning units has an average of 125 units per week
and a standard deviation of 15 units per week.
The lead time between an order placement and order delivery
is 4 weeks.
The inventory holding cost of one air-conditioning unit for the
retailer is 10, while the cost of placing an order is 50.
How much inventory should the retailer keep in safety stock to
satisfy a service level of 90%?
How often should the retailer place an order and how many
air-conditioning units should he order?
42
Q system Example (2)
The standard deviation of the demand distribution for the lead time is:
L = t L = 15 4 = 30
From the tables of Normal Distribution for a service level of 90%, z = 1.28.
Safety stock, thus, derives as:
Safety stock = z x L = 1.28 x 30 = 38.4 or 39 units
The reorder point becomes:
Re order point = Average demand during lead time + safety stock
R = 125 x 4 + 39 = 539 units
The annual demand is D = 125 units / week x 52 weeks = 6500 units
Economic Order Quantity:
2 DS 2 (52 125) 50
EOQ = = 255
H 10
Therefore, anytime the inventory drops to 539 units, the retailer needs to place
an order for 255 units.
43
Periodic Review System (P)
An alternative inventory control system is the Periodic review system
(P) or fixed interval reorder system or periodic reorder system.
In the periodic review system (P) an items inventory position is
reviewed periodically rather than continuously.
Such a system can simplify delivery scheduling, because it establishes
a routine.
A new order is always placed at the end of each review and the time
between orders (TBO) is fixed at P.
Demand is a random variable. So, demand between reviews varies.
In a P system, the lot size Q may change from one order to the next,
but the time between orders is fixed.
44
Periodic Review System (P)
From the original EOQ assumptions the following are maintained:
There are no constraints on the size of the lot
Decisions for one item are independent of decisions for other items
There is no uncertainty in lead times or supply.
The downward-sloping line represents on-hand
inventory.
inventory
47
P System Example
The annual demand is: D = 125 units / week 52 weeks (per year) = 6500 units.
The length of time between reviews is:
P = (EOQ/D)x52 weeks = 255 / 6500x52 = 2.04 2 weeks
The standard deviation for the protection interval P+L is:
P + L = L P + L = 15 2 + 4 37
For a service level of 90%, z = 1.28.
Therefore, the target inventory level T becomes:
In the case of P-system, the safety stock held is 47 (=1.28x37) units, which is
larger than the safety stock held in the case of Q-system (39 units).
48
P-system advantages
49
Q-system advantages
50
Hybrid Systems
Various hybrid inventory control systems merge some but not all the features
of P and Q systems.
Optional Replenishment system
A system used to review the inventory position at fixed time in intervals and, if
the position has dropped to (or below) a predetermined level, to place a
variable-sized order to cover expected needs. The new order is large enough to
bring the inventory position up to a target inventory, similar to T for P-system.
Still, orders are not placed after a review unless the inventory position has
dropped to the predetermined minimum level (acts as the reorder point R in Q-
system).
Base-Stock system
A system that issues a replenishment order Q each time a withdrawal is made,
for the exact amount of the withdrawal. This one-for-one replacement policy
maintains the inventory position at a base-stock level equal to expected
demand during lead time plus safety stock (acts as reorder point in Q system).
However, order sizes now vary to keep the inventory position at R at all times.
Since this position is the lowest IP possible that will maintain a specified service
level, the base-stock system may be used to minimize cycle inventory.
51