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Chapter 12 - Inventory Management
Chapter 12 - Inventory Management
Management
Chapter 12 –
Inventory Management
Work-in-process
Undergone some change but not completed
During most of the time the product being made is in fact
sitting idle
Maintenance/repair/operating (MRO)
Necessary to keep machinery and processes productive
Finished goods
Completed product awaiting shipment
© 2008 Prentice Hall, Inc. 12 – 4
Inventory Management
How inventory items can be classified
Percent of Percent of
Item Number of Annual Annual Annual
Stock Items Volume Unit Dollar Dollar
Number Stocked (units) x Cost = Volume Volume Class
#10286 20% 1,000 $ 90.00 $ 90,000 38.8% A
72%
#11526 500 154.00 77,000 33.2% A
Percent of Percent of
Item Number of Annual Annual Annual
Stock Items Volume Unit Dollar Dollar
Number Stocked (units) x Cost = Volume Volume Class
#12572 600 $ 14.17 $ 8,502 3.7% C
A Items
80 –
70 –
60 –
50 –
40 –
30 –
20 – B Items
10 – C Items
0 – | | | | | | | | | |
10 20 30 40 50 60 70 80 90 100
Percent of inventory items Figure 12.2
on hand
(maximum
inventory Q
level) 2
Minimum
inventory
0
Time
Figure 12.3
© 2008 Prentice Hall, Inc. 12 – 14
Minimizing Costs
Objective is to minimize total costs
Minimum
total cost
Annual cost
Holding cost
curve
D
= (S)
Q
Order quantity
= (Holding cost per unit per year)
2
= Q (H)
2
Optimal order quantity is found when annual setup cost equals annual
holding cost
D Q
S = H
Q 2
Solving for Q*
2DS = Q2H
Q2 = 2DS/H
Q* = 2DS/H
2DS
Q* =
H
2(1,000)(10)
Q* = = 40,000 = 200 units
0.50
Expected Demand D
number of = N = =
orders Order quantity Q*
1,000
N= = 5 orders per year
200
Number of working
Expected days per year
time between = T =
orders N
250
T= = 50 days between orders
5
Q*
Inventory level (units)
Slope = units/day = d
ROP
(units)
Time (days)
Figure 12.5 Lead time = L
© 2008 Prentice Hall, Inc. 12 – 24
Reorder Point Example
Demand = 8,000 iPods per year
250 working day year
Lead time for orders is 3 working days
D
d=
Number of working days in a year
= 8,000/250 = 32 units
ROP = d x L
= 32 units per day x 3 days = 96 units
t Time
Figure 12.6
Annual inventory
= (Maximum inventory level)/2
level
Maximum Q Q d
inventory level = p –d =Q 1–
p p p
Q d
Holding cost = Maximum inventory level (H) = 1– H
2 2 p
2DS
Q*p =
H[1 - (d/p)]
2DS
Q* =
H[1 - (d/p)]
2(1,000)(10)
Q* = = 80,000
0.50[1 - (4/8)]
= 282.8 or 283
2DS
Q* =
annual demand rate
H 1–
annual production rate
Discount Discount
Number Discount Quantity Discount (%) Price (P)
1 0 to 999 no discount $5.00
2 1,000 to 1,999 4 $4.80
Table 12.2
2(5,000)(49)
Q2* = = 714 cars/order
(.2)(4.80)
2(5,000)(49)
Q3* = = 718 cars/order
(.2)(4.75)
2(5,000)(49)
Q2* = = 714 cars/order
(.2)(4.80) 1,000 — adjusted
2(5,000)(49)
Q3* = = 718 cars/order
(.2)(4.75) 2,000 — adjusted
0 1,000 2,000
Figure 12.7
Order quantity
© 2008 Prentice Hall, Inc. 12 – 39
Quantity Discount Models
Steps in analyzing a quantity discount
1. For each discount, calculate Q*
2. If Q* for a discount doesn’t qualify, choose
the smallest possible order size to get the
discount
3. Compute the total cost for each Q* or
adjusted value from Step 2
4. Select the Q* that gives the lowest total cost
Table 12.3
Q4
Q2
On-hand inventory
Q1 P
Q3