Professional Documents
Culture Documents
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S
H
Q
D
TC
Where
H
Q
S
Q
D
TC
EOQ
EOQ Total Costs
Total annual costs = annual ordering costs + annual holding costs
The EOQ Formula
Minimize the TC by ordering the EOQ:
H
DS
EOQ
2
=
When to Order:
The Reorder Point
Without safety stock:
With safety stock:
days/weeks in time lead
units in demand ly daily/week
units in point reorder where
=
=
=
=
L
d
R
dL R
units in stock safety where =
+ =
SS
SS dL R
EOQ Example
Weekly demand = 240 units
No. of weeks per year = 52
Ordering cost = $50
Unit cost = $15
Annual carrying charge = 20% of unit cost
Lead time = 2 weeks
EOQ Example Solution
year units D / 480 , 12 240 52 = =
year per unit per H 3 $ 15 2 . 0 = =
units
H
DS
Q 645 98 . 644
3
50 480 , 12 2 2
~ =
= =
units dL R
H
Q
S
Q
D
TC
480 2 240
$1,934.94 5 . 967 44 . 967
3
2
645
50
645
480 , 12
2
= = =
= + =
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Setup cost
Setup costs apply when the required items are produced in the organization & comprise the following factors
1. Cost of setting up the process i.e.,
(a) Setting up necessary equipment & making necessary tool changes
(b) Instructing the operator and follow up
(c) Building up the skill in operator
2. Cost of scrap
3.Cost of planning production & controlling
(a) Scheduling & following up of work
(b) Accounting for job costs
(c) Preparing necessary production control paper work
EPQ (Economic Production Quantity) Assumptions
Same as the EOQ except: inventory arrives in increments & is
drawn down as it arrives
EPQ Equations
Adjusted total cost:
Maximum inventory:
Adjusted order quantity:
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I
S
Q
D
TC
MAX
EPQ
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p
d
Q I
MAX
1
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p
d
H
DS
EPQ
1
2
EPQ Example
Annual demand = 18,000 units
Production rate = 2500 units/month
Setup cost = $800
Annual holding cost = $18 per unit
Lead time = 5 days
No. of operating days per month = 20
EPQ Example Solution
month units p month units d / 2500 ; / 1500
12
000 , 18
= = =
units
p
d
H
DS
Q 2000
2500
1500
1 18
800 000 , 18 2
1
2
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units
p
d
Q I
MAX
800
2500
1500
1 2000 1 =
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400 , 14 200 , 7 200 , 7
18
2
800
800
2000
000 , 18
2
= + =
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S
Q
D
TC
MAX
EPQ Example Solution (cont.)
The reorder point:
With safety stock of 200 units:
units SS dL R 575 200 5
20
1500
= + = + =
units dL R 375 5
20
1500
= = =
Quantity Discount Model Assumptions
Same as the EOQ, except:
Unit price depends upon the quantity ordered
Adjusted total cost equation:
PD H
Q
S
Q
D
TC
QD
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2
Quantity Discount Procedure
Calculate the EOQ at the lowest price
Determine whether the EOQ is feasible at that
price
Will the vendor sell that quantity at that price?
If yes, stop if no, continue
Check the feasibility of EOQ at the next higher
price
Continue to the next slide ...
QD Procedure (continued)
Continue until you identify a feasible EOQ
Calculate the total costs (including total item
cost) for the feasible EOQ model
Calculate the total costs of buying at the
minimum quantity required for each of the
cheaper unit prices
Compare the total cost of each option &
choose the lowest cost alternative
Any other issues to consider?
QD Example
Annual Demand = 5000 units
Ordering cost = $49
Annual carrying charge = 20%
Unit price schedule:
Quantity Unit Price
0 to 999 $5.00
1000 to 1999 $4.80
2000 and over $4.75
QD Example Solution
Step 1
( ) feasible not Q
P
718
75 . 4 2 . 0
49 000 , 5 2
75 . 4 $
=
=
=
( ) feasible not Q
P
714
80 . 4 2 . 0
49 000 , 5 2
80 . 4 $
=
=
=
( ) feasible Q
P
700
00 . 5 2 . 0
49 000 , 5 2
00 . 5 $
=
=
=
QD Example Solution (Cont.)
Step 2
700 , 25 $ 5000 00 . 5 00 . 5 2 . 0
2
700
49
700
000 , 5
700
= + + =
= Q
TC
725 , 24 $ 5000 80 . 4 80 . 4 2 . 0
2
1000
49
1000
000 , 5
1000
= + + =
= Q
TC
50 . 822 , 24 $ 5000 75 . 4 75 . 4 2 . 0
2
2000
49
2000
000 , 5
2000
= + + =
= Q
TC
What if Demand is Uncertain?
Safety Stock and Service Level
Order-cycle service level is the probability that
demand during lead time wont exceed on-hand
inventory.
Risk of a stockout = 1 (service level)
More safety stock means greater service level and
smaller risk of stockout
Safety Stock and Reorder Point
Without safety stock:
With safety stock:
days in time lead
units in demand daily
units in point reorder where
=
=
=
=
L
d
R
dL R
units in stock safety where =
+ =
SS
SS dL R
Reorder Point Determination
R = reorder point
d = average daily demand
L = lead time in days
z = number of standard deviations associated with
desired service level
o = standard deviation of demand during lead time
dL
dL
z dL R
z SS
o
o
+ =
=
i.e.,
Safety Stock Example
Daily demand = 20 units
Lead time = 10 days
S.D. of lead time demand = 50 units
Service level = 90%
Determine:
1. Safety stock
2. Reorder point
Safety Stock Solution
Step 1 determine z
Step 2 determine safety stock
Step 3 determine reorder point
units 264 64 10 20 = + = + = SS dL R
28 . 1 : B Appendix From = z
units 64 50 28 . 1 = = SS
Inventory Record Accuracy
Inaccurate inventory records can cause:
Lost sales
Disrupted operations
Poor customer service
Lower productivity
Planning errors and expediting
Two methods are available for checking record accuracy
Periodic counting-physical inventory
Cycle counting-daily counting of pre-specified items provides the
following advantages:
Timely detection and correction of inaccurate records
Elimination of lost production time due to unexpected stock outs
Structured approach using employees trained in cycle counting